Method for producing injection-molded and in-mold decorated article and mold for injection molding with in-mold decoration

ABSTRACT

In a manufacturing method for injection-molded and in-mold decorated articles including injection of molding resin ( 4 ) into a molding space ( 3 ) defined by a decorating film ( 5 ) and a mold ( 1 ), the molding space has a product molding space ( 31 ) and a resin-discharging-use molding space ( 33 ) which is formed around the product molding space and into which the molding resin is let to flow for discharge of the molding resin from the product molding space. The molding resin is injected into the product molding space, and while part of the injected molding resin is discharged from the product molding space into the resin-discharging-use molding space, the molding resin is filled into the product molding space.

TECHNICAL FIELD

The present invention relates to a manufacturing method forinjection-molded and in-mold decorated articles, the method including,with a decorating film set between a first mold element and a secondmold element placed in opposition to each other, injecting moltenmolding resin into a molding space defined by the decorating film andthe first mold element, and solidifying the molding resin filled in themolding space by the injection while decorating a surface of the moldingresin with the decorating film. The invention also relates to a mold forinjection-molding with in-mold decoration for use in this manufacturingmethod.

BACKGROUND ART

In recent years, from the demand for being light, thin, short and small,molded articles of electronic equipment or various types of componentshave been under an increasing desire for the most possible reduction intheir thicknesses. In order to meet this desire, there has been provideda resin molded article manufacturing method described in Japaneseexamined patent publication No. 3044027, for example, as a resin moldedarticle manufacturing method using an injection mold which is composedof a molding space matching external shapes of various products and anauxiliary space surrounding the entire periphery of the molding space.

It is described in the publication that this molded articlemanufacturing method of the prior art is an invention for obtaining aresin molded article by injecting molten molding resin from a gateportion into the auxiliary space that surrounds the entire periphery ofthe molding space, which is a space defined by mutually oppositelyplaced two molds, and thereafter injecting molding resin into themolding space via the auxiliary space. In this case, it is alsodescribed that since the resin can be made to flow into the moldingspace in all directions of the auxiliary space, it is easily achievableto obtain a uniform resin inflow even with a thin molding space.

Now the prior-art manufacturing method is explained with reference toFIGS. 50A and 50B, where FIG. 50A is a schematic sectional view of themolds in a state that those spaces are formed by the two molds, and FIG.50B is a schematic plan view showing flows of the molding resin duringthe injection of molten molding resin into the individual spaces of FIG.50A.

As shown in FIG. 50A, the two molds, i.e., a first mold element 501 anda second mold element 502 are placed in opposition to each other andclamped together, by which a molding space 503 and an auxiliary space504 communicatively positioned over the entire outer periphery of themolding space 503 is formed between inner surfaces of the molds 501 and502. The auxiliary space 504 is provided with a gate portion 514 thatallows molten molding resin to be injected thereinto from external ofthe mold 501.

In this state shown above, as molten molding resin is injected from thegate portion 514 into the auxiliary space 504, the molding resininjected into the auxiliary space 504 is, as shown in FIG. 50B, let toflow so as to go around the entire outer periphery of the molding space503 and then flow toward generally central portion of the molding space503 (arrows ‘d’ in the figure show the directions of flow of the moldingresin), by which the molding resin is introduced from the auxiliaryspace 504 to the molding space 503. That is, the molding resin injectedinto the auxiliary space 504 through the gate portion 514 is introducedinto the molding space 503 in every direction that runs from theauxiliary space 504 toward the molding space 503. As a result of theintroduction of the molding resin into the molding space 503 in everydirection as shown above, the molding resin can be supplied in agenerally uniform state into the thin molding space 503.

Then, after the introduced molding resin is solidified, the first moldelement 501 and the second mold element 502 are separated away from eachother and a thin resin molded article 505 is taken out. Furtherthereafter, decoration of the surface of the resin molded article 505 isperformed by, for example, printing or coating, by which aninjection-molded and then decorated article is manufactured.

However, in such a prior-art resin molded article manufacturing methodas shown above, since the decoration of the resin molded article isperformed after the formation of the resin molded article, that is,since the decoration is performed as an after processing, there areproblems that multilayer decoration would entail a poor productionefficiency and moreover that a cubic configuration, if the moldedarticle has, would make it hard to do an easy printing, or aprecision-demanding pattern would make it impossible to do coating.

Further, since the molten molding resin injected from the gate portion514 into the auxiliary space 504 is injected into the molding space 503via the auxiliary space 504, that is, since the molten molding resinflows in from the auxiliary space 504, which is positioned so as tosurround the entire outer periphery of the molding space 503, toward themolding space 503, there is a problem as shown below.

That is, fore end portions of the molten molding resin containing alarge amount of gases are concentrated at a center portion of themolding space 503, and as a result, gases are highly likely to remain atthe center portion of the formed resin molded article 505. Furthermore,in the state that gases are likely to remain as shown above, the moltenmolding resin collides with itself at places near the central portion ofthe molding space 503, causing a fear that a resin burn 552 due to thegases may occur near the central portion of a resin molded portion 505 aformed by the molding space 503 (in addition, numeral 505 b in thefigure denotes a resin molded portion formed by the auxiliary space 504)as shown in FIG. 52, which is a schematic view of the resin moldedarticle 505. Moreover, as shown in FIG. 51, because of the collisions ofthe molten molding resin in vicinities of the central portion of themolding space 503, a weld 551 is more likely to occur in vicinities ofthe generally central portion of the resin molded portion 505 a formedby the molding space 503, as another problem.

Also, since the molten molding resin is injected into the molding space503 via the auxiliary space 504 that surrounds the entire outerperiphery of the molding space 503 to fulfill the injection of generallyuniform molding resin injection into the molding space 503 in everydirection, there is a restriction that the filling of molding resin intothe auxiliary space 504, which is positioned on one side opposite to thegate portion 514 with the molding space 503 interposed therebetween,need to be done before the start of the filling of the molding resininto the molding space 503. The presence of such a restriction causes aproblem that the configuration and placement of the molding space 503and the auxiliary space 504 is substantially under quite rigidlimitations.

DISCLOSURE OF THE INVENTION

Accordingly, an object of the present invention is to provide, forsolving the above-described issues, a manufacturing method forinjection-molded and in-mold decorated article, the method being capableof achieving the decoration of molded articles of various configurationswith high precision and high efficiency, as well as of preventingoccurrence of welds or the like in central portion or the like of theresin molded article to be molded, for the process of in-mold decorationsimultaneous with injection molding including, setting a decorating filmbetween a first mold element and a second mold element placed inopposition to each other, injecting molten molding resin into a moldingspace defined by the decorating film and the first mold element, andsolidifying the molding resin filled in the molding space by theinjection while decorating a surface of the molding resin with thedecorating film, and also to provide a mold for injection-molding within-mold decoration to be used in the above-described manufacturing.

In order to achieve the above object, the present invention has thefollowing constitutions.

According to a first aspect of the present invention, there is provideda manufacturing method for an injection-molded and in-mold decoratedarticle, the method including, setting a decorating film between a firstmold element and a second mold element placed in opposition to eachother, injecting molten molding resin into a molding space defined bythe decorating film and the first mold element, and solidifying themolding resin filled in the molding space, thereby manufacturing theinjection-molded and in-mold decorated article, wherein

the molding space includes:

-   -   a product molding space, and    -   a resin-discharging-use molding space which is formed so as to        be adjacent to and communicative with at least part of a        periphery of the product molding space and into which the        molding resin is let to flow for discharge of the molding resin        from the product molding space,

the method comprising:

-   -   injecting the molding resin into the product molding space;    -   discharging part of the injected molding resin from the product        molding space into the resin-discharging-use molding space;    -   completing filling of the molding resin into the product molding        space and the resin-discharging-use molding space; and    -   solidifying the molding resin while decorating a surface of the        molding resin with the decorating film, so that the        injection-molded and in-mold decorated article is manufactured.

According to a second aspect of the present invention, there is providedthe manufacturing method for the injection-molded and in-mold decoratedarticle as defined in the first aspect, wherein

the molding space includes a resin-injection-use molding space which isformed so as to be adjacent to and communicative with at least part of aperiphery of the product molding space and into which the molding resinis injected from outside of the molding space,

the method further comprising:

-   -   injecting the molding resin from outside of the molding space        into the resin-injection-use molding space; and    -   making the injected molding resin flow from the        resin-injection-use molding space into the product molding        space, by which injection of the molding resin into the product        molding space is fulfilled.

According to a third aspect of the present invention, there is providedthe manufacturing method for the injection-molded and in-mold decoratedarticle as defined in the first aspect, wherein

the molding space includes:

-   -   a first said product molding space and a second said product        molding space, which are communicative with each other, and    -   a common said resin-discharging-use molding space which is        placed between the first product molding space and the second        product molding space and which is communicative with the first        product molding space and the second product molding space,

the method further comprising:

-   -   injecting the molding resin into the first product molding space        and the second product molding space;    -   discharging, into the common resin-discharging-use molding        space, part of the molding resin injected into the first product        molding space and part of the molding resin injected into the        second product molding space; and    -   completing filling of the molding resin into the first product        molding space, the second product molding space and the common        resin-discharging-use molding space.

According to a fourth aspect of the present invention, there is providedthe manufacturing method for the injection-molded and in-mold decoratedarticle as defined in the second aspect, wherein

the molding space includes:

-   -   a first said product molding space and a second said product        molding space, which are communicative with each other, and    -   a common said resin-injection-use molding space,

the method further comprising:

-   -   injecting the molding resin from outside of the molding space        into the common resin-injection-use molding space;    -   making the injected molding resin flow from the        resin-injection-use molding space into the first product molding        space and the second product molding space, by which filling of        the molding resin is fulfilled.

According to a fifth aspect of the present invention, there is providedthe manufacturing method for the injection-molded and in-mold decoratedarticle as defined in the first aspect, wherein injection of the moldingresin is performed in a state that, with the decorating film placedbetween the first mold element and the second mold element, the firstmold element and the second mold element are clamped to make the moldingspace hermetically closed.

According to a sixth aspect of the present invention, there is providedthe manufacturing method for the injection-molded and in-mold decoratedarticle as defined in the fifth aspect, wherein, after the filling ofthe molding resin into the molding space, a capacity of the moldingspace is reduced while compressing the filled molding resin.

According to a seventh aspect of the present invention, there isprovided the manufacturing method for the injection-molded and in-molddecorated article as defined in the first aspect, wherein, with thedecorating film is placed between the first mold element and the secondmold element and making the first mold element and the second moldelement approached by each other so as to be in a condition the moldingspace is opened, injection of the molding resin is performed, andthereafter the first mold element and the second mold element is clampedso that a capacity of the molding space is reduced while compressing thefilled molding resin.

According to an eighth aspect of the present invention, there isprovided a mold for injection-molding with in-mold decoration formanufacturing an injection-molded and in-mold decorated article, bysetting a decorating film placed between a first mold element and asecond mold element placed in opposition to each other, injecting moltenmolding resin into a molding space defined by the decorating film andthe first mold element, and solidifying the molding resin filled in themolding space while decorating a surface of the molding resin with thedecorating film, wherein

the molding space comprises:

-   -   a product molding space into which the molten molding resin is        injected; and    -   a resin-discharging-use molding space which is formed so as to        be adjacent to and communicative with at least part of a        periphery of the product molding space and into which part of        the molding resin injected into the product molding space is let        to flow and discharged from the product molding space.

According to a ninth aspect of the present invention, there is providedthe mold for injection-molding with in-mold decoration as defined in theeighth aspect, wherein the molding space further comprises aresin-injection-use molding space which is formed so as to becommunicative with at least part of the product molding space and intowhich the molding resin is injected from outside of the molding space,and moreover which lets the injected molding resin flow into the productmolding space so that injection of the molding resin into the productmolding space is fulfilled.

According to a tenth aspect of the present invention, there is providedthe mold for injection-molding with in-mold decoration as defined in theeighth aspect, further comprising a film holding portion which is formedas generally protruded portion on a surface of the second mold element,with which the decorating film in the resin-discharging-use moldingspace is to be brought into contact by the injection of the moldingresin into the resin-discharging-use molding space, and which serves tohold placement of the decorating film while removing looseness of thedecorating film by putting the decorating film into close contact with asurface of the protruded portion.

According to an eleventh aspect of the present invention, there isprovided the mold for injection-molding with in-mold decoration asdefined in the tenth aspect, further comprising a plurality of suctionportions which are set at the film holding portion or its vicinities inthe surface of the second mold element and which serve for sucking andholding the decorating film in contact therewith.

According to a twelfth aspect of the present invention, there isprovided the mold for injection-molding with in-mold decoration asdefined in the eighth aspect, further comprising:

a recess portion formed along an entirety or part of an outer peripheryof the molding space in either one of the first mold element or thesecond mold element; and

a protruded engagement portion which is formed on the other of the firstmold element or the second mold element so as to correspond to theplacement of the recessed portion and engage with the recess portion inthe clamping state of the first mold element and the second moldelement, wherein

in the clamping state of the first mold element and the second moldelement with the decorating film interposed therebetween, tension isimparted to the decorating film by making the recessed portion and theengagement portion engaged with each other via the decorating film.

According to a thirteenth aspect of the present invention, there isprovided the mold for injection-molding with in-mold decoration asdefined in the eighth aspect, further comprising an air vent portion fordischarging gas present in the resin-discharging-use molding space tooutside of the molding space in a vicinity of a boundary with theproduct molding space in the resin-discharging-use molding space.

According to a fourteenth aspect of the present invention, there isprovided the mold for injection-molding with in-mold decoration asdefined in the eighth aspect, wherein

the molding space comprises:

a first said product molding space;

a second said product molding space which is communicative with thefirst product molding space; and

a common said resin-discharging-use molding space into which part of themolding resin injected into the first product molding space and part ofthe molding resin injected into the second product molding space aredischarged and let to flow.

According to a fifteenth aspect of the present invention, there isprovided the mold for injection-molding with in-mold decoration asdefined in the ninth aspect, wherein

the molding space comprises:

a first said product molding space;

a second said product molding space which is communicative with thefirst product molding space; and

a common said resin-injection-use molding space into which the moldingresin is injected from outside of the molding space and which lets theinjected molding resin injected into the first product molding space andthe second product molding space so that filling of the molding resin isfulfilled.

According to the first aspect of the present invention, in themanufacturing method for injection-molded and in-mold decoratedarticles, the molding space comprises a product molding space, and aresin-discharging-use molding space into which the molding resininjected into the product molding space is let to flow, in which themolding resin is injected into the product molding space, and moreoverwhile part of the injected molding resin is discharged from the productmolding space into the resin-discharging-use molding space, the moldingresin is filled into the product molding space. As a result of this, inthe product molding space, flows of the molding resin directed from theposition of the injection of the molding resin for the discharge towardthe resin-discharging-use molding space can be formed. Therefore, in theproduct molding space where a molded article as a product part isformed, not that the molding resin flows in every direction but thatflow directions of the molding resin can be restricted so thatcollisions of the molding resin itself will not occur. Thus, occurrenceof welds can reliably be prevented in the product molding space.

Also, part of the molding resin filled into the product molding space islet to flow into the resin-discharging-use molding space. Therefore,even if such a weld occurs, the weld occurs within the product moldingspace that is not used as a product part but is a removal portion,causing no problems.

Further, gases contained in the molding resin are also let to flow intothe resin-discharging-use molding space along the restricted flowdirection, being accumulated there together with the molding resin.Thus, no gas stagnated portion is formed in the product molding space,so that resin burns due to gas can be prevented.

Accordingly, there occur no welds or resin burns on the surface of themolded article formed by the product molding space, which becomes afinal product part, thus allowing the product quality to be improved.

Also, since welds and resin burns can be prevented, decoration with thedecorating film can be carried out on the surface of the molded articleformed in the product molding space along with the molding process.Thus, efficient decoration can be fulfilled.

Further, since such injection-molding with in-mold decoration using adecorating film can be fulfilled, almost no effects are produced on theproductivity even if the decoration is of multiple colors. Besides,since the decorating film is formed in compliance with a moldconfiguration, decoration can be applied even to three-dimensionalconfiguration surfaces, to which the decoration could not be appliedwith normal printing. Thus, high precision decoration can be efficientlyachieved.

According to the second aspect of the invention, the molding spacefurther includes a resin-injection-use molding space into which themolding resin is injected from outside of the molding space. As a resultof this, while the molding resin is injected from outside of the moldingspace into the resin-injection-use molding space, the injected moldingresin can be made to flow from the resin-injection-use molding spaceinto the product molding space, by which the injection of the moldingresin into the product molding space can be carried out. Thus, aninjection hole portion through which the molding resin is injected isnot provided directly in the product molding space but provided in theresin-injection-use molding space, which is another space. As a resultof this, damage of the decorating film due to jet pressure of themolding resin injected through the injection hole portion or the likecan be prevented, and besides more uniformized injection of the moldingresin into the product molding space can be achieved.

According to the third and fourth aspects of the present invention, evenin cases where the molding space includes two product molding spaces,there can be provided a manufacturing method having the above-describedeffects. Further, even if the resin-injection-use molding space or theresin-discharging-use molding space is not provided independently foreach of the individual product molding spaces in the molding space, forexample, providing a common resin-injection-use molding space or acommon resin-discharging-use molding space makes it possible to achieveefficient spatial arrangement in the molding space. Therefore, anefficient manufacturing method for in-mold injection-molded decoratedarticles can be provided in terms of size reduction of the mold oreffective use of molding resin to be used or the like.

According to the fifth to seventh aspects of the present invention,various molding methods which have been in use for injection molding canbe applied to the manufacturing method for injection-molded and in-molddecorated articles according to the present invention. For example,performing the injection of molding resin into the molding space inhermetic closed state makes it possible to eliminate molding resin thatwould be exposed at mold peripheral portions. Also, reducing thecapacity of the molding space after the injection of molding resin makesit possible to successfully perform the injection of the molding resineven in such cases where the molding space is a thin-type space or thelike. Moreover, density of the injected molding resin can be enhanced,making it possible to manufacture high-density molded articles.

According to the eighth aspect of the present invention, in the mold forinjection-molding with in-mold decoration, the molding space comprises aproduct molding space, and a resin-discharging-use molding space intowhich the molding resin injected into the product molding space is letto flow. As a result of this, it becomes possible to fulfill manufactureof a molded article in which while the molding resin is injected intothe product molding space, part of the injected molding resin can bedischarged from the product molding space into the resin-discharging-usemolding space, thereby filling the molding resin into the productmolding space, and in the product molding space, flows of the moldingresin directed from the position of the injection of the molding resinfor the discharge toward the resin-discharging-use molding space can beformed. Accordingly, occurrence of welds can reliably be prevented inthe product molding space. Also, even if such a weld occurs, the weldoccurs within the product molding space that is not used as a productpart but is a removal portion, causing no problems.

Furthermore, gas contained in the molding resin is also let to flow intothe resin-discharging-use molding space along the restricted flowdirection, being accumulated there together with the molding resin.Thus, no gas stagnated portion is formed in the product molding space,so that resin burns due to gas can be prevented.

Accordingly, there can be provided a mold for injection-molding within-mold decoration, with which mold there occur no welds or resin burnson the surface of the molded article formed by the product moldingspace, which becomes a final product part, thus allowing the productquality to be improved.

According to the ninth aspect of the invention, the molding spacefurther includes a resin-injection-use molding space into which themolding resin is injected from outside of the molding space. As a resultof this, it becomes possible to fulfill manufacture of a molded articlein which while the molding resin is injected from outside of the moldingspace into the resin-injection-use molding space, the injected moldingresin can be made to flow from the resin-injection-use molding spaceinto the product molding space, by which the injection of the moldingresin into the product molding space can be carried out. Thus, aninjection hole portion through which the molding resin is injected isnot provided directly in the product molding space but provided in theresin-injection-use molding space, which is another space. As a resultof this, it becomes possible to provide a metal mold for in-moldinjection-molding decoration, with which mold damage of the decoratingfilm due to jet pressure of the molding resin injected through theinjection hole portion or the like can be prevented, and besides moreuniformized injection of the molding resin into the product moldingspace can be achieved.

According to the tenth aspect of the present invention, placement of thedecorating film can be held while looseness of the decorating film isremoved by putting the decorating film into close contact therewith bythe film holding portion. As a result of this, there occurs no formationof marks of wrinkles or looseness of the decorating film on the surfaceof the molded article, and moreover the decoration can be achieved atspecified sites on the surface of the molded article with highreliability. Thus, in-mold injection-molded decorated articles of highprecision can be manufactured.

According to the eleventh aspect of the present invention, at the filmholding portion or its vicinities are provided a plurality of suctionportions which serve for sucking and holding the decorating film incontact therewith. As a result of this, the holding of the decoratingfilm can be achieved more reliably.

According to the twelfth aspect of the present invention, the first moldelement or the second mold element includes the recessed portion, and anengagement portion which is engageable with the recessed portion, inwhich tension can be imparted to the decorating film by the recessedportion and the engagement portion being engaged with each other via thedecorating film. As a result of this, in the clamping of the first moldelement and the second mold element via the decorating film, tension canautomatically be imparted to the decorating film, so that occurrence ofwrinkles or looseness of the decorating film in the molding space can besuppressed.

According to the thirteenth aspect of the present invention, air ventportions are provided in the resin-discharging-use molding space. As aresult of this, gas converged to the resin-discharging-use molding spacecan reliably be removed through the individual air vent portions. Also,the air vent portions are positioned at places near the periphery of theproduct molding space in the resin-discharging-use molding space, bywhich gases slightly remaining in the product molding space can beremoved concurrently.

According to the fourteenth and fifteenth aspects of the presentinvention, even in cases where the molding space includes a plurality ofthe resin-injection-use molding spaces or a plurality of theresin-discharging-use molding spaces, the effects by the foregoingindividual aspects can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and features of the present invention willbecome clear from the following description taken in conjunction withthe preferred embodiments thereof with reference to the accompanyingdrawings, in which:

FIG. 1 is a schematic sectional view showing a state before injection ofmolding resin in an injection-molded and in-mold decorated articlemanufacturing method according to a first embodiment of the presentinvention;

FIG. 2 is a schematic sectional view showing a state of injection of themolding resin in the injection-molded and in-mold decorated articlemanufacturing method of the first embodiment;

FIG. 3 is a schematic sectional view showing a state that the moldingresin has been filled in the injection-molded and in-mold decoratedarticle manufacturing method of the first embodiment;

FIG. 4 is a schematic sectional view showing a state that the moldedarticle is released from the mold in the injection-molded and in-molddecorated article manufacturing method of the first embodiment;

FIG. 5 is a schematic plan view of a first mold element of the firstembodiment;

FIGS. 6A, 6B, 6C and 6D are schematic sectional views of the first moldelement of FIG. 5, where FIG. 6A is a sectional view taken along theline B-B, FIG. 6B is a sectional view taken along the line C-C, FIG. 6Cis a sectional view taken along the line D-D, and FIG. 6D is a sectionalview taken along the line E-E;

FIG. 7 is a schematic plan view of a second mold element of the firstembodiment;

FIGS. 8A and 8B are schematic sectional views of the second mold elementof FIG. 7, where FIG. 8A is a sectional view taken along the line G-G,and FIG. 8B is a sectional view taken along the line F-F;

FIG. 9 is a spatial planar arrangement view of the molding space of thefirst embodiment;

FIG. 10 is a spatial arrangement view in a cross section taken along theline A-A of FIG. 9;

FIGS. 11A and 11B are partly enlarged sectional views showing stretchingrecesses of the first embodiment, where FIG. 11A shows a state beforeengagement of the engagement member, and FIG. 11B shows a state in whichthe engagement member is engaged;

FIG. 12 is a spatial arrangement view showing the directions of flows ofthe molding resin in the molding space of the first embodiment;

FIG. 13 is a schematic plan view of an injection-molded and in-molddecorated article of the first embodiment;

FIG. 14 is a schematic plan view of frame molded article parts of thefirst embodiment;

FIG. 15 is a schematic plan view of product molded article parts of thefirst embodiment;

FIG. 16 is a schematic sectional view showing the structure of adecorating film of the first embodiment;

FIG. 17 is a schematic sectional view of a decorating film according toanother example of the first embodiment;

FIG. 18 is a schematic sectional view showing an injection-molded andin-mold decorated article (injection-compression-molded and in-molddecorated article) manufacturing method according to a second embodimentof the present invention, showing a state before the injection ofmolding resin;

FIG. 19 is a schematic sectional view showing a state of injection ofmolding resin in the injection-molded and in-mold decorated articlemanufacturing method of the second embodiment;

FIG. 20 is a schematic sectional view showing a state that the moldingresin has been filled and compressed in the injection-molded and in-molddecorated article manufacturing method of the second embodiment;

FIG. 21 is a schematic sectional view showing a state that the moldedarticle is released from the mold in the injection-molded and in-molddecorated article manufacturing method of the second embodiment;

FIG. 22 is a schematic plan view of the first mold element of the secondembodiment;

FIG. 23 is a spatial arrangement view of the molding space according toWorking Example 1 in the respective embodiments of the presentinvention;

FIG. 24 is a spatial arrangement view of the molding space according toWorking Example 2;

FIG. 25 is a spatial arrangement view of the molding space according toWorking Example 3;

FIG. 26 is a spatial arrangement view of the molding space according toWorking Example 4;

FIG. 27 is a spatial arrangement view of the molding space according toWorking Example 5;

FIG. 28 is a spatial arrangement view of the molding space according toWorking Example 6;

FIG. 29 is a spatial arrangement view of the molding space according toWorking Example 7;

FIG. 30 is a spatial arrangement view of the molding space according toWorking Example 8;

FIG. 31 is a spatial arrangement view of the molding space according toWorking Example 9;

FIG. 32 is a spatial arrangement view of the molding space according toWorking Example 10;

FIG. 33 is a spatial arrangement view of the molding space according toWorking Example 11;

FIG. 34 is a spatial arrangement view of the molding space according toWorking Example 12;

FIG. 35 is a spatial arrangement view of the molding space according toWorking Example 13;

FIGS. 36A, 36B, 36C and 36D are schematic plan views of injection-moldedand in-mold decorated articles in the respective embodiments, where FIG.36A shows a molded article having no transparent window portions, FIG.36B shows a molded article having a transparent window portionstretching over the generally whole article, FIG. 36C shows a moldedarticle having a transparent window portion in part, and FIG. 36D showsa molded article which is formed transparent in the entirety of thearticle;

FIG. 37 is a schematic plan view showing an example of the form ofpartitioning protrusions according to the respective embodiments;

FIG. 38 is a schematic plan view showing another example of the form ofpartitioning protrusions;

FIG. 39 is a schematic plan view showing yet another example of the formof partitioning protrusions;

FIG. 40 is a schematic plan view showing still another example of theform of partitioning protrusions;

FIG. 41 is a schematic plan view showing still another example of theform of partitioning protrusions;

FIG. 42 is a schematic plan view showing an example of the placementaspect of suction pins according to the respective embodiments;

FIG. 43 is a schematic plan view showing another example of theplacement aspect of suction pins;

FIG. 44 is a schematic plan view showing still another example of theplacement aspect of suction pins;

FIG. 45 is a schematic plan view showing still another example of theplacement aspect of suction pins;

FIG. 46 is a schematic plan view showing still another example of theplacement aspect of suction pins;

FIG. 47 is a schematic plan view showing an example of the placementaspect of the stretching recess according to the respective embodiments;

FIG. 48 is a schematic plan view showing still another example of theplacement aspect of the stretching recess;

FIG. 49 is a schematic plan view showing still another example of theplacement aspect of the stretching recess;

FIGS. 50A and 50B are views showing an injection-molded articlemanufacturing method according to a prior art, where FIG. 50A is asectional view of the mold and FIG. 50B is a view showing the directionsof flows of the molding resin in the mold;

FIG. 51 is a view showing a state that a weld has occurred in aninjection-molded article of the prior art; and

FIG. 52 is a view showing a state that a resin burn has occurred in aninjection-molded article of the prior art.

BEST MODE FOR CARRYING OUT THE INVENTION

Before the description of embodiments of the present invention proceeds,definitions of the terms used in Claims and Specification of the presentinvention are described.

The term “molding space” refers to a space which is defined by adecorating film and a first mold element when the decorating film is setbetween the first mold element and a second mold element placed inopposition to each other, where the space makes it possible to form aresin molded article (i.e., a whole molded article including a productportion and a removal portion of the formation of the product)corresponding to the form of the space when the resin is injected intothe space and further solidified.

The term “product molding space” refers to a space where a resin moldedarticle that can become the product portion out of the molding space isformed, i.e., a space where the product portion derived from removingthe removal portion from the resin molded article is formed.

The term “resin-discharging-use molding space” refers to a space whichis part of the molding space, and which is formed adjacent to andcommunicative with at least part of the periphery of the product moldingspace, and into which part of the molding resin injected into theproduct molding space is filled via the product molding space, theresin-discharging-use molding space being a space necessarily providedin the molding space of the present invention. In other words, theresin-discharging-use molding space is a space into which part of themolding resin injected into the product molding space is discharged fromthe product molding space so as to flow into the space. The part of theresin molded article formed in this resin-discharge space is in manycases removed from the resin molded article as the removal portion, sothat a product is formed from the resin molded article by this removal.However, it is also possible that the part formed in theresin-discharging-use molding space is used as part of the productportion without being removed. It is noted that theresin-discharging-use molding space may be referred also as an addedmolding space.

The term “resin-injection-use molding space” refers to a space which ispart of the molding space, and which is formed adjacent to andcommunicative with at least part of the periphery of the product moldingspace, and moreover into which the molding resin is injected fromoutside of the molding space. The resin-injection-use molding space isalso a space into which the molding resin injected from outside is madeto flow into the product molding space via the resin-injection-usemolding space so that the molding resin is injected into the productmolding space. The part of the resin molded article formed in thisresin-injection-use molding space is, in many cases, removed from theresin molded article as the removal portion, so that a product is formedfrom the resin molded article by this removal. However, it is alsopossible that the part formed in the resin-injection-use molding spaceis used as part of the product portion without being removed. It isnoted that the resin-injection-use molding space may be referred also asan auxiliary molding space.

With regard to the description of embodiments of the present invention,first, the conceptual constitution of the present invention is describedin detail.

In the present invention, an injection-molding and in-mold decoratingmethod is adopted as the decoration method for an injection-moldedarticle. The injection-molding and in-mold decoration method is a methodincluding, with a decorating film set between a first mold element and asecond mold element of an injection mold, clamping the molds together,injecting molten molding resin from a gate portion into a molding spacedefined by the decorating film and the first mold element, andsolidifying the injected molding resin, to thereby obtain aninjection-molded and in-mold decorated article in which the decoratingfilm and the molding resin have been integrated together.

Besides, in some cases, a substrate sheet forming the decorating filmmay be peeled off in a later step. Since the injection-molding andin-mold decorating method uses a decorating film that is previouslyprinting processed, almost no effects are produced on the productivityeven if the decoration is of multiple colors. Also, since the decoratingfilm is formed in compliance with a B mold configuration, decoration canbe applied even to three-dimensional configuration surfaces, to whichthe decoration could not be applied with normal printing. Moreover,patterning is possible on the decorating film.

Further, in the present invention, the molding space comprises aplurality of product molding spaces and outer-outer-frame molding spacessurrounding the product molding spaces, respectively, the productmolding spaces and the outer-frame molding spaces communicating witheach other, respectively. For example, the outer-frame molding spacecomprises a resin-injection-use molding space closer to the gateportion, and a resin-discharging-use molding space located away from thegate portion and with the product molding space therebetween, whereafter or while molten molding resin is filled into the product moldingspaces via the resin-injection-use molding spaces, part of the moldingresin filled into the product molding spaces is let to flow into theresin-discharging-use molding spaces and thereby filled in.

Also, by the formation of the individual spaces, it can be said that thefirst mold element has, in its recessed portions formed in its surface,a product molded article forming portion capable of forming the productmolding space between the first mold element and the decorating film, aninjection-space molded article forming portion capable of forming theresin-injection-use molding space between the first mold element and thedecorating film, and a discharge-space molded article forming portioncapable of forming the resin-discharging-use molding space between thefirst mold element and the decorating film. Also, the injection-spacemolded article forming portion is positioned adjacent to the productmolding space forming portion, and the discharge-space molded articleforming portion is positioned adjacent to the product molding spaceforming portion.

Then, for such fluidization of the molding resin as described above, thepresent invention adopts a metal mold for injection-molded and in-molddecorated, the mold being characterized in that the molding space isformed plate-like or other rectangular shaped and that given an averagecross-sectional area S1 (mm²) of the product molding spaces, an averagethickness T1 (mm) of the product molding spaces, an averagecross-sectional area S2 (mm²) of the outer-frame molding spaces, and anaverage thickness T2 (mm) of the outer-frame molding spaces, there holdrelations that S1≧4×S2 and that T1≧T2.

That is, by setting the average thickness and average cross-sectionalarea of the product molding space to ones not less than the averagethickness and average cross-sectional area of the outer-frame moldingspaces, there can be made up a mold which allows molten molding resin tobe filled into the product molding spaces, for example, via theresin-injection-use molding spaces and thereafter filled into theresin-discharging-use molding spaces. In this connection, thesenumerical values can be set from experiment results shown in Table 1:TABLE 1 Molded article No. 1 2 3 4 5 6 7 8 Average cross-sectional 8.08.0 8.0 8.0 6.0 4.0 3.5 4.0 area of product molding space portions, S1(mm²) Average thickness of 0.8 1.2 1.0 1.1 1.1 1.1 1.1 1.0 productmolding space portions, T1 (mm) Average cross-sectional 1.0 1.0 1.0 1.01.0 1.0 1.0 1.0 area of outer-frame molding space portions, S2 (mm²)Average thickness of 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 outer-frame moldingspace portions, T2 (mm) 4 × S2 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0Acceptance or Rejection x ∘ ∘ ∘ ∘ ∘ x ∘ as to desired flow (∘) or not(x) of molding resin

In test results of Table 1, with respect to the acceptance or rejectionof desired flow of the molding resin, symbol “o” shows a case whereafter or while the molten molding resin were filled into the productmolding spaces via the resin-injection-use molding spaces, part of themolding resin filled into the product molding spaces flowed into theresin-discharging-use molding spaces and filled therein, and symbol “x”shows a case where not. It is noted that the “cases where not: x”, inwhich flows themselves of the molding resin into theresin-discharging-use molding spaces were observed but not determined asa completely filled state, are distinguished from the “cases wherefilled: o.”

As a result of formation of a mold having such a configuration, sincethe fore end portion of the molding resin injected into the moldingspace is fed into the resin-discharging-use molding spaces, gasesgenerated in the molding resin can be fed into the resin-discharging-usemolding spaces along with the molding resin, so that the remainingamount of gases in the product molding spaces can be reduced. Also,since collisions of the molten molding resin itself in vicinities ofcentral portions of the product molding spaces can be avoided, resinburns due to the gases never occur. Further, since collisions of themolten molding resin itself in vicinities of central portions of theproduct molding spaces of the product molding spaces can be avoided, asite of occurrence of a weld, if any, can be shifted to theresin-discharging-use molding space.

In addition, with the adoption of the injection-molding and in-molddecorating method, it is highly likely that a large wrinkle occurs at aposition of the decorating film corresponding to the position ofoccurrence of the weld, causing the appearance of the injection-moldedand in-mold decorated article to be impaired. However, with theabove-described constitution, since the site of the occurrence of theweld can be shifted to the resin-discharging-use molding space, thisproblem can be solved at the same time.

Furthermore, in the present invention, the mold for injection-moldingwith in-mold decoration which mold is capable of preventing occurrenceof small wrinkles of the decorating film that could occur to the productmolding spaces due to the adoption of the injection-molding and in-molddecorating method may be so structured as to have a first mold elementand a second mold element and have partitioning protrusions provided atthe outer-frame molding spaces that surround the product molding spaces,respectively, of the recessed surface of the second mold element.

In the injection-molding and in-mold decorating method, generally, thedecorating film would be burdened with dragging loads due to the flow ofthe molten molding resin, so that the decorating film would be loosenedresultantly. However, with the partitioning protrusions provided in therecessed surface of the second mold element, the decorating film can bemade less liable to loosening because of the following reasons.

That is, molten molding resin, after filled into the resin-injection-usemolding spaces, go beyond the partitioning protrusions provided betweenthe resin-injection-use molding spaces and the product molding spaces,entering into the product molding spaces. In this case, the moltenmolding resin is filled into the product molding spaces while holdingand stretching the decorating film by the partitioning protrusions.Accordingly, it is less likely that small wrinkles occur to thedecorating film surrounded by the partitioning protrusions.

It is noted that positions where the partitioning protrusions are formedmay be contiguous to the product molding space or separate awaytherefrom. That is, the molding space surrounded by the partitioningprotrusions may either be the product molding space alone or include theproduct molding spaces and the outer-frame molding space. Further, thepartitioning protrusions may be provided continuously like a loop ordiscontinuously.

Further, in the present invention, suction pins may be provided at thepartitioning protrusions in the mold for injection-molding with in-molddecoration.

The suction pins have a function of sucking and fixing the decoratingfilm to the second mold element as well as a function of removing air orcontaminations remaining between the decorating film and the second moldelement as well as the gases generated from the substrate sheet of thedecorating film or the like. The suction pins may be formed into acylindrical or block-like or other rectangular shapes. The suction pinsmay also be provided within the molding spaces surrounded by thepartitioning protrusions.

Moreover, in the present invention, the mold for injection-molding within-mold decoration may be provided with a stretching recess in thereference surface of the outer periphery of the outer-frame moldingspaces.

Even if the molding spaces surrounded by the partitioning protrusionsare formed without any small wrinkles, it is still likely that smallwrinkles occur outside the partitioning protrusions, particularly in theresin-discharging-use molding spaces. Because of the small wrinkles, theposition of decoration of the injection-molded and in-mold decoratedarticle may be slightly shifted.

However, with the stretching recess provided in the mold forinjection-molding with in-mold decoration, any looseness of thedecorating film that has occurred in the resin-discharging-use moldingspaces is relieved by the stretching recess, and moreover the tension ofthe whole decorating film in the molding space is maintained at anappropriate level. Therefore, the position of decoration of theinjection-molded and in-mold decorated article is never shifted.

Furthermore, the stretching recess may be provided continuously like aloop or discontinuously. In addition, it is preferable to provide thestretching recess on the entire outer periphery of the molding spaceslike a loop, because their effects are produced uniformly in everydirection.

Also in the present invention, the mold for injection-molding within-mold decoration may be provided with air vent pins at positionscontiguous to the product molding spaces in the resin-discharging-usemolding space.

In the injection-molding and in-mold decorating method, since thedecorating film is set on the second mold element side during themolding, gases of the molding resin derived from the second mold elementside less escape, so that molding resin gases less escape as comparedwith common injection molds. This necessitates a contraption for gasesescape to the first mold element side. Also, the molding resin gases arecontained relatively more in amount at fore end portions of the moltenmolding resin.

Thus, with the provision of the air vent pins at positions where thefore end portions of the molten molding resin on the first mold elementside are finally concentrated (i.e., the resin-discharging-use moldingspaces), the molding resin gases concentrated at theresin-discharging-use molding spaces can be let to escape through thegaps between the air vent pins and the first mold element. Particularlywhen the air vent pins are provided at positions nearest to the productmolding spaces (i.e., positions contiguous to the product moldingspaces), not only the molding resin gas converged to theresin-discharging-use molding space but also the molding resin gas thatcould slightly remain in the product molding spaces can be let toefficiently escape.

The width over which each air vent pin and the product molding space isin contact with each other is preferably 0.1-1.0 mm. With the contactwidth larger than 1.0 mm, the portion of this contact would remain as amark in the product molding spaces even after the cutting of theinjection-molded and in-mold decorated article into the product moldingspaces and the resin-discharging-use molding space, causing theappearance to worsen. On the other hand, with the contact portionsmaller than 0.1 mm, the molding resin gases slightly remaining in theproduct molding spaces less escape.

In addition, the air vent pins may be formed into a cylindrical or otherblock-like rectangular shape.

As shown above, by performing injection-molding and in-mold decoratingwith the use of this mold for injection-molding with in-mold decoration,there can be obtained an injection-molded and in-mold decorated articlewhich has a plurality of product molding portions and outer-framemolding portions communicating with the product molding portions,respectively, and in which an air vent mark is formed at theresin-discharging-use molding portions in the outer-frame moldingportions contiguous to the product molding portions. It is noted thatthe air vent mark may extend through or not.

FIRST EMBODIMENT

Hereinbelow, a first embodiment of the present invention is described indetail with reference to the accompanying drawings. In the accompanyingdrawings to be used in the description of individual embodiments of theinvention, like component members are designated by like referencenumerals.

First, as schematic explanatory views schematically showing amanufacturing method for injection-molded and in-mold decorated articlesaccording to this first embodiment, schematic sectional views of a firstmold element and a second mold element are shown in FIGS. 1, 2, 3 and 4.Also, a plan view of the first mold element is shown in FIG. 5, asectional view at line B-B of the first mold element of FIG. 5 is shownin FIG. 6A, a sectional view at line C-C is shown in FIG. 6B, asectional view at line D-D is shown in FIG. 6C, and a sectional view atline E-E is shown in FIG. 6D. Further, a plan view of the second moldelement is shown in FIG. 7, a sectional view at line F-F of the secondmold element of FIG. 7 is shown in FIG. 8A, and a sectional view at lineG-G is shown in FIG. 8B. It is noted that the cross sections of thefirst mold element shown in FIGS. 1 to 4 are cross sections taken alongthe line A-A of the first mold element of FIG. 5, and the cross sectionsof the first mold element are cross sections taken along the line A-A ofthe second mold element of FIG. 7.

First, as shown in FIG. 1, in the manufacturing method forinjection-molded and in-mold decorated articles according to the firstembodiment, two molds of a first mold element 1 and a second moldelement 2 constituting the metal mold for injection-molding with in-molddecoration are used, and the molds 1, 2 are so placed that theirsurfaces on which recessed portions are formed confront each other, anda decorating film 5 for adding patterns on the surface of the resinmolded article is placed between the molds 1, 2. In this state, moltenmolding resin is injected a molding space defined by the recessedportion of the first mold element 1 and the surface of the decoratingfilm 5, and while the molding resin is cooled and solidified, thesurface of the molding resin in contact with the decorating film 5 isdecorated, by which an injection-molded and in-mold decorated articlecan be obtained.

The first mold element 1, as shown in FIG. 5 and FIGS. 6A to 6D, has agenerally quadrilateral shape as viewed in a plan view, and at fourperipheral edge portions on its one surface, a reference surface 11,which serves as the upper surface of protruded portion to be broughtinto contact with the second mold element 2, is formed in a continuationalong the quadrilateral four peripheral edge portions. In an innerportion surrounded by the reference surface 11 is formed a recessedportion 12 having a configuration corresponding to the external shape ofthe resin molded article. Further, between the recessed portion 12 andthe reference surface 11, a later-described stretching recess 15 whichis a portion for imparting tension to the decorating film 5 is formedalong the inner periphery of the reference surface 11.

Also, as shown in FIGS. 5 and 6D, a gate portion 14 which is aninjection port for performing injection of molten molding resin isformed at a place near a vertical and horizontal center of the firstmold element 1, i.e., near a center of the inner bottom portion of therecessed portion 12. In addition, air vent pins 19 are provided, asrequired, at the inner bottom portions of the recessed portion 12 of thefirst mold element 1 in this first embodiment as shown in FIG. 5 andFIG. 6B, but the makeup of the air vent pins 19 will be described later.

Meanwhile, as shown in FIG. 7 and FIGS. 8A and 8B, the second moldelement is generally equal in size of the external shape to the firstmold element 1 so as to be correspondent thereto, being formed into agenerally quadrilateral shape, as viewed in a plan view, with generallyequal placement and width to the reference surface 11 of the first moldelement 1, where a reference surface 21, which serves as the uppersurface of protruded portion to be brought into direct contact with thereference surface 11 of the first mold element 1, is formed incontinuation to the quadrilateral peripheries. Further, in an innerportion surrounded by the reference surface 21 are formed a recessedportion 22 having a configuration corresponding to the external shape ofthe resin molded article and a later-described stretching recess 15which is a portion for imparting tension to the decorating film 5.

The first mold element 1 and the second mold element 2 having structuresshown above are placed in opposition to each other in such alignmentthat their respective reference surface 11 and the reference surface 21confront each other (i.e., so that the reference surface 11 and thereference surface 21 can be coincident with each other), and thedecorating film 5 is placed between the first mold element 1 and thesecond mold element 2 (the state shown in FIG. 1). As a result of this,it has become possible to make the inner space of the recessed portion12 of the first mold element 1 and the inner space of the recessedportion 22 of the second mold element 2 placed in contact with eachother via the decorating film 5. In such a state, the reference surface11 of the first mold element 1 and the reference surface 21 of thesecond mold element 2 are clamped together so as to be brought intocontact with each other via the decorating film 5, by which a moldingspace 3 is formed between the decorating film 5 and the first moldelement 1. The spatial configuration of the molding space 3, i.e.,height, width and thickness of the space correspond to specified height,width and thickness of a resin molded article to be formed. By themolding space 3 being formed in this way, an injection-molded andin-mold decorated article 10 of specified dimensions can be obtained byinjecting molten resin (molding resin) 4 into the molding space 3 andthereafter solidifying the resin.

It is noted here that the molding space 3 formed by the first moldelement 1 and the second mold element 2 being clamped with thedecorating film 5 sandwiched therebetween has a plurality of spaces. Asan example, the molding space 3 includes product molding spaces,resin-discharging-use molding space and resin-injection-use moldingspace. A planar arrangement view of individual spaces in such a moldingspace 3 is shown in FIG. 9, and a cross-sectional view at line A-A ofFIG. 9 is shown in FIG. 10. By using these drawings, the placement ofthe individual spaces is explained in detail. It is noted that in theplan view of FIG. 9, those spaces are placed on a plan view of the firstmold element as the first mold element 1 is viewed from the surface ofthe decorating film 5. Also, FIG. 9 is a drawing intended to clarify theplacement of the individual spaces and, for an easier understandingthereof, only principal components of the first mold element 1 are shownwhile details of the structure are partly omitted in the figure.Besides, in FIGS. 9 and 10, hatching patterns are added in order to makeit easier to visually recognize those spaces.

As shown in FIGS. 9 and 10, in the molding space 3 surrounded anddefined by the recessed portion 12 of the first mold element 1 and thedecorating film 5, four product molding spaces 31 (which are an exampleof the first product molding space and the second product molding space)are placed so as to be generally equidistantly spaced from one anotherwithout contact therebetween. These product molding spaces 31 are spaceswhere portions that form final product portions out of a resin moldedarticle formed by the molding spaces. As a result of such placement offour product molding spaces 31, the metal mold for injection-moldingwith in-mold decoration comprises the first mold element 1 and thesecond mold element 2 is a multiple metal mold capable of molding aplurality of products at one time.

Further, the molding space 3 includes a resin-injection-use moldingspace 32 (an example of the common resin-injection-use molding space)and a resin-discharging-use molding space 33 (an example of the commonresin-discharging-use molding space), the spaces being spacesrespectively communicating with and adjacent to part of outerperipheries of the individual product molding spaces 31. Theresin-injection-use molding space 32 is placed so as to communicate withthe resin-injection-use gate portion 14 placed at a place near thegenerally center of the first mold element 1. More concretely, as shownin FIG. 9, the resin-injection-use molding space 32 is placed in agenerally cross shape, as viewed in a plan view, between the individualfour product molding spaces 31. On the other hand, theresin-discharging-use molding space 33 is placed in a generally O-shape,as viewed in a plan view, between the inner peripheral portions of therecessed portion 12 of the first mold element 1 and the four productmolding spaces 31. Also, respective boundary portions among the productmolding spaces 31, the resin-injection-use molding space 32 and theresin-discharging-use molding space 33 are communicated with each otherwithout any partitioning. As a result of this, it has become possiblethat the resin injected through the gate portion 14 into theresin-injection-use molding space 32, while filling theresin-injection-use molding space 32 itself, partly flows into theindividual product molding spaces 31 so as to be filled into theindividual product molding spaces 31, and moreover part of the resinthat has flowed into the individual product molding spaces 31 furtherflows in so as to be discharged into the resin-discharging-use moldingspace 33. In addition, in FIG. 10, a space surrounded by the recessedportion 12 of the first mold element 1 and the decorating film 5 is themolding space 3, while a space surrounded by the recessed portion 22 ofthe second mold element 2 and the decorating film 5 is present inaddition and this space is a space which disappears when presseddownward in the figure by the resin injection into the molding space 3,i.e., pressed against the inner bottom surface of the recessed portion22 of the second mold element 2. Further, the resin-injection-usemolding space 32 and the resin-discharging-use molding space 33 areplaced so as to surround the outer peripheries of the individual productmolding spaces 31, and therefore it can be said that outer-frame moldingspaces which are spaces of outer frame portions surrounding theindividual product molding spaces 31 are made up by theresin-injection-use molding space 32 and the resin-discharging-usemolding space 33.

In connection to the placement of individual spaces shown above, thestructure of the second mold element 2 is further explained. As shown inFIGS. 7 and 8A, partitioning protrusions 23 protruded toward the firstmold element 1 to be placed in opposition thereto are placed in theinner bottom surface of the recessed portion 22 of the second moldelement 2 so as to surround the outer peripheries of its portionscorresponding to the respective product molding spaces 31. That is, theindividual partitioning protrusions 23 formed to surround the entireouter peripheries of the portions corresponding to the respectiveproduct molding spaces 31 are placed and formed in vicinities ofboundaries between the resin-injection-use molding space 32 and theresin-discharging-use molding space 33 and the individual productmolding spaces 31. Also, as shown in FIGS. 7 and 8A, a plurality ofsuction pins 25 are provided on upper surfaces of the respectivepartitioning protrusions 23 and in vicinities of the respectivepartitioning protrusions 23 in molding spaces 3 surrounded by therespective partitioning protrusions 23. It is noted that the individualsuction pins 25 are connected to a suction device via unshown suctionpassages.

When molding resin is injected into the individual product moldingspaces 31, the decorating film 5 is brought into close contact with theinner bottom portion of the recessed portion 22 of the second moldelement 2 while being stretched. In this case, these partitioningprotrusions 23 having functions of, by making the decorating film 5brought into close contact with the surfaces of the protrusive bumpportions, increasing the surface area of the close contact of thedecorating film 5, thereby preventing occurrence of looseness or thelike of the decorating film 5 and moreover holding the close contactstate of the decorating film 5 to the inner bottom surface of therecessed portion 22. Moreover, by the provision of the suction pins 25on the individual partitioning protrusions 23 or in vicinities thereof,it is more reliably ensured to achieve and hold the close contact of thedecorating film 5 to the respective protruded portions. It is noted thatin this embodiment, the partitioning protrusions 23 are an example ofthe film holding portion for holding the placement of the decoratingfilm 5 while removing its looseness, and the suction pins 25 are anexample of the suction part.

Next described are the stretching recesses 15, which are hollow recessedportions provided in the reference surface 11 and the recessed portion12 that are brought into contact with each other via the decorating film5 during the process of clamping of the first mold element 1 and thesecond mold element 2. The stretching recesses 15 are provided in orderto reduce the looseness of the decorating film 5 occurring in themolding space 3 when the decorating film 5 is placed between the firstmold element 1 and the second mold element 2.

Now a partly enlarged schematic sectional view of a vicinity of thestretching recesses 15 in a pre-clamping state in which the decoratingfilm 5 is set between the first mold element 1 and the second moldelement 2 is shown in FIG. 11A, and a partly enlarged schematicsectional view of a clamped state is shown in FIG. 11B. With referenceto these figures, the function of the stretching recesses 15 isexplained in detail.

As shown in FIG. 11A, the stretching recess 15 of the first mold element1 is engaged with an engagement member 16 which is an example of theengagement part to be engaged with the hollow recessed portion of thestretching recess 15, in which engagement state the engagement member 16is protruded from the reference surface 11 so as to be engaged also withthe stretching recess 15 of the second mold element 2. Also, thedecorating film 5 is set on the second mold element 2 set below in thefigure, where the decorating film 5 is in a loosened state.

In this state shown above, when the first mold element 1 and the secondmold element 2 are clamped together as shown in FIG. 11B, lower portionof the engagement member 16 in the figure is engaged with the stretchingrecess 15 of the second mold element 2. In this case, by this engagementbeing effectuated via the decorating film 5, part of the decorating film5 is pushed into the stretching recess 15 of the second mold element 2,absorbing the looseness so that occurrence of wrinkles on the decoratingfilm 5 can be inhibited.

This embodiment has been described on a case where the stretching recess15 is formed in the first mold element 1 and the engagement member 16 isengaged with this stretching recess 15. However, the present inventionis not limited to such a case. For example, instead of such a case,protruded portions may preliminarily be formed in the first mold element1. Even in such a case, making the bump portions engaged with thestretching recesses 15 of the second mold element 2 allows the sameeffects as with the use of the engagement member 16 to be obtained.

The stretching recess 15 is provided preferably on the entire outerperiphery of the molding space 3, and preferably with a depth of 0.5 to5 mm and a width of 0.5 to 7 mm. Too small depths and widths would leadto a weaker reduction effect for the looseness of the decorating film 5,while too large depths and widths would cause the strength of the metalmold to lower.

Further, the stretching recess 15 may be provided either on both the Amold element 1 and the B mold element 2, or on only one of them. Whenstretching recess 15 is provided on both, those stretching recesses maybe different in depth or width from each other.

Next, air vent pins (an example of the air vent part) to be provided inthe resin-discharging-use molding space 33 in the first mold element 1are described. The air vent pins 19 are provided so that gases containedin molten molding resin are let to efficiently escape outside fromwithin the molding space 3.

According to that purpose, as shown in FIG. 6B, positions where theindividual air vent pins 19 are provided are places where fore endportions of the molten molding resin 4 are finally filled, i.e., theresin-discharging-use molding space 33 that is located farthest from thegate portion 14.

However, in fact, it is more likely that gases which could slightlyremain in the individual product molding spaces 31 matters rather thangases which concentrate to the resin-discharging-use molding space 33.Therefore, it is preferable that the air vent pins 19 are provided atplaces in the resin-discharging-use molding space 33 closer to theproduct molding spaces 31 in order to efficiently remove the gases thatcould slightly remain.

Thus, with the air vent pins 19 provided at places in theresin-discharging-use molding space 33 farthest from the gate portion 14and adjacent to the product molding spaces 31, not only the gasesconverged to the resin-discharging-use molding space 33 but also gasesslightly remaining in the individual product molding spaces 31 can belet to escape.

The shape, size and position of each air vent pin 19 as well as thewidth of its contact with the product molding spaces 31 is determined asrequired depending on the size and shape of each product molding space31, the distance from the gate portion 14, the magnitude of flowresistance of the molding resin 4 attributed to depressions andprojections of the metal mold for injection-molding with in-molddecoration (i.e., the first mold element 1 and the second mold element2), and the like.

Also, the number of the air vent pins 19 to be provided is determined,as required with a view to smoother discharge of the gases, depending onthe capacities of the molding space 3 and the individual product moldingspaces 31 as well as on the rate at which the gases should bedischarged.

Particularly with the injection-molding and in-mold decoration method,since the gases of the molding resin 4 less escapes from the second moldelement 2 that is brought into contact with the decorating film 5 at itsinner bottom surface of the recessed portion 22, it is useful to providesuch individual air vent pins 19 and moreover molding resins 4 involvinghigher amounts of gases generation become also usable because the mattercan be resolved as shown above.

As shown in FIG. 4, the injection-molded and in-mold decorated article10 formed by the resin filled into the molding space 3 is made up ofproduct molded article portions 30, which are portions formed by resinfilled in the product molding spaces 31, an injection-space moldedarticle portion 42, which is a portion formed in the resin-injection-usemolding space 32, and a discharge-space molded article portion 43, whichis a portion formed in the resin-discharging-use molding space 33. It isnoted that the injection-space molded article portion 42 and thedischarge-space molded article portion 43 are placed and formed on theperipheries of the individual product molded article portions 30, thesemolded article portions can be said to be an outer-frame molded articleportion 40 as a whole. In the molding of the injection-molded andin-mold decorated article 10 shown above, by the provision of the airvent pins 19, a plurality of air vent holes 20 are formed in theinjection-molded and in-mold decorated article 10 as shown in FIG. 4.Such air vent holes 20 as shown above can also be used for positioninginvolved in cutting the injection-molded and in-mold decorated article10 into the product molded article portions 30 and the outer-framemolded article portion 40 in later process after the injection molding.

Also, since the air vent holes 20 are formed in the discharge-spacemolded article portion 43, there can be obtained an advantage that theair vent holes 20 can be separated from the product molded articleportions 30 as part of the outer-frame molded article portion 40, sothat the product molded article portions 30 are not adversely affected.

The molding resin 4 may be given by using thermoplastic resins such asacrylic resin, polycarbonate resin, styrene resins, polyamide resins,NORYL resins, polyester resins, olefin resins, urethane resins, and onacrylonitrile butadiene styrene resins.

Further, as shown in FIG. 4, a plurality of ejector pins 24 forextruding the injection-molded and in-mold decorated article 10 formedin the molding space 3 so that the injection-molded and in-molddecorated article 10 is released from the recessed portion 12 of thefirst mold element 1 are provided in vicinities of peripheral portion ofthe inner bottom portion of the recessed portion 12 of the first moldelement 1. In addition, instead of the case where the releasing isimplemented by the individual ejector pins 24 as shown above, the airvent pins 19 may have the function of mold releasing operation.

Next, a method for manufacturing the injection-molded and in-molddecorated article 10 with the use of the first mold element 1, thesecond mold element 2 and the decorating film 5 of the above-describedstructures is described in detail.

First, as shown in FIG. 1, the first mold element 1 and the second moldelement 2 are placed in opposition to each other so that theirrespective recessed portions 12, 22 confront each other (i.e., so thatthe recessed portion 22 of the second mold element 2 faces upward andthe recessed portion 12 of the first mold element 1 faces downward asviewed in FIG. 1), and the decorating film 5 is placed between the firstmold element 1 and the second mold element 2 so that the surface onwhich having decorating layers 50 provided thereon is placed on thefirst mold element 1 side. During this process, the molds 1, 2 are sopositioned that the reference surface 11 of the first mold element 1 andthe reference surface 21 of the second mold element 2 become coincidentwith each other via the decorating film 5, while the decorating film 5is also positioned relative to the molds 1, 2 at the same time.

After this positioning, as shown in FIG. 2, the first mold element 1 andthe second mold element 2 are clamped via the decorating film 5. As aresult of this clamping, as shown in FIGS. 9 and 10, a molding space 3,which includes individual product molding spaces 31, aresin-injection-use molding space 32 and resin-discharging-use moldingspace 33, is formed by the recessed portion 12 of the first mold element1 and the decorating film 5. Also, in this clamping, as shown in FIGS.11A and 11B, when the engagement members 16 (not shown in FIGS. 1 and 2)engaged with the stretching recesses 15 of the first mold element 1 isengaged with the stretching recess 15 of the second mold element 2 viathe decorating film 5, tension is imparted to the decorating film 5, bywhich wrinkles, looseness and the like are removed.

Thereafter, as shown in FIG. 2, injection of molten molding resin 4 intothe molding space 3 through the gate portion 14 is started. Thisinjected molding resin 4 is injected first into the resin-injection-usemolding space 32, pressing the decorating film 5 toward the second moldelement 2 side, by which the pressed decorating film 5 is brought intocontact with the partitioning protrusions 23 and moreover fixed by thesuction pins 25. Thereafter, the molten molding resin 4 fills theresin-injection-use molding space 32 in vicinities of the gate portion14 and moreover enters the individual product molding spaces 31 beyondthe partitioning protrusions 23 on the vicinities side.

In this operation, the molten molding resin 4 increasingly fills themolding space 3 while pressing and gradually stretching the decoratingfilm 5 with the partitioning protrusions 23, thus making the decoratingfilm 5 less likely to loosen. Accordingly, small wrinkles less occurs tothe decorating film 5 surrounded by the individual partitioningprotrusions 23.

Then, after the molten molding resin 4 has filled the product moldingspaces 31, or as this filling goes on, part of the molding resin 4injected into the individual product molding spaces 31 enters into theresin-discharging-use molding space 33, so that theresin-discharging-use molding space 33 is filled with the molding resin4. As a result of this, the molding space 3 is filled with the moldingresin 4 (see FIG. 3). Also, in the process of such filling, most of thegases generated from the molding resin 4 is converged to theresin-discharging-use molding space 33, and further the gases convergedby the air vent pins 19 is discharged to outside of the molding space 3.Further, by the individual air vent pins 19 being provided in theresin-discharging-use molding space 33 in the vicinities of theindividual product molding spaces 31, gas that slightly remains in theproduct molding spaces 31 is also discharged outside and removed bythose air vent pins 19.

Now flows of molding resin 4 injected into the molding space 3 arevisually shown in FIG. 12 by using a spatial arrangement view (schematicplan view) of the molding space 3. As shown in FIG. 12, the moltenmolding resin 4 injected through the gate portion 14 placed at a placenear the generally center of the molding space 3 is first injected intothe resin-injection-use molding space 32 directly communicating with thegate portion 14, and further the injected molding resin 4 is filled intothe resin-injection-use molding space 32 in such flow directions F1(arrows in the figure) as spreading generally radially from the gateportion 14. Along with the progress of this injection process, themolding resin 4 spreads in the generally radial flow directions F1,flowing from the resin-injection-use molding space 32 into theindividual product molding spaces 31 so as to fill the product moldingspaces 31. The molding resin 4 further spreading generally radially,part of the molding resin 4 injected into the product molding spaces 31flows in so as to be discharged into the resin-discharging-use moldingspace 33, so that the molding resin 4 is filled into the overall moldingspace 3.

Since the molding resin 4 is injected so as to spread in the moldingspace 3 in such generally radial flow directions F1 as shown in FIG. 12,it becomes practicable to concentrate generated gases to theresin-discharging-use molding space 33, which is a space serving asterminal end portions of injection of the molding resin 4. Moreover,collisions of the injected molding resin 4 itself do not occur nowherein the individual product molding spaces 31, so that occurrence of weldsin the individual product molding spaces 31 can be prevented.

After the molding resin 4 has been filled into the molding space 3 inthis way, the molding resin 4 that has been in the molten state iscooled and solidified. Thereafter, as shown in FIG. 4, as the clampingof the first mold element 1 and the second mold element 2 is released,the ejector pins 24 are projected, causing the injection-molded andin-mold decorated article 10 to be released from the mold. Thedecorating layers 50 of the decorating film 5 are peeled off from asubstrate sheet 51 and resultantly fixed to the surface of theinjection-molded and in-mold decorated article 10 that has been incontact with the decorating film 5. Thus, the decoration on theinjection-molded and in-mold decorated article 10 has been achieved.

A schematic plan view of the injection-molded and in-mold decoratedarticle 10 formed as shown above is shown in FIG. 13. As shown in FIG.13, the injection-molded and in-mold decorated article 10 includes theindividual product molded article portions 30, the injection-spacemolded article portion 42 and the discharge-space molded article portion43, which are formed integrally. Also, the individual product moldedarticle portions 30 have, on their surfaces, N-shaped patterns by thedecorating layers 50. Further, partitioning recesses 16, which aretraces of the partitioning protrusions 23 in the second mold element 2,are formed in the frame molded article portion 40 so as to surround theperipheries of the individual product molded article portions 30. Aplurality of suction holes or suction protrusions 26, which are tracesof the suction pins 25 in the second mold element 2 (depending on theconfiguration of the suction pins 25, the traces of the suction pins 25may be either hole shaped or protrusion shaped), are formed on theindividual partitioning recesses 16 or in their vicinities. Moreover, aplurality of air vent holes 20, which are traces of the air vent pins19, are formed in the frame molded article portion 40. Therefore, noneof the partitioning recesses 16, the suction holes or suctionprotrusions 26, and the air vent holes 20 are formed in the individualproduct molded article portions 30.

The injection-molded and in-mold decorated article 10 obtained in thisway is, as shown in FIGS. 14 and 15, cut from the injection-space moldedarticle portion 42 and the discharge-space molded article portion 43 atboundary portions with the individual product molded article portions 30by a specified size, thus being divided into four product molded articleportions 30 (see FIG. 14) and a outer-frame molded article portion 40(see FIG. 15), so that the individual product molded article portions30, for example, are obtained as product portions. It is noted that themethod of cutting may be implemented by cutting work, laser beammachining, Thomson machining, mold press working, chisel machining(including thermal process), radio frequency machining or the like.Besides, in FIGS. 13, 14 and 15, hatching patterns are added in order tomake it easier to recognize divisions of those molded article portionsor the like.

Next, the structure of the decorating film 5 to be used in thisembodiment is explained. As shown in FIG. 16, the decorating film 5 isformed of the substrate sheet 51 and the decorating layer 50 provided onthe substrate sheet 51, the decorating layer 50 includes a pattern layer52 (a portion forming the N-shaped pattern), an adhesion layer 53 or thelike.

The substrate sheet 51 may be a laminated film of a resin selected fromamong polycarbonate resin, polyamide resin, polyimide resin, polyesterresin, acrylic resin, olefin resin, urethane resin, acrylonitrilebutadiene styrene resin, and the like, or a laminated film orcopolymerized film of two or more kinds selected from thereamong.

The thickness of the substrate sheet 51 is preferably 5 to 500 μm. Thesubstrate sheet, if less than 5 μm in thickness, would be poor athandlability in the process of setting to the mold such as the placementand clamping between the molds 1, 2, making subsequent molding stepsunstable. The substrate sheet 51 having a thickness beyond 500 μm wouldbe so rigid that its adhesion to the partitioning protrusions 23 woulddeteriorate, causing in some cases wrinkle traces or the like of thedecorating film 5 to occur to the surface of the injection-molded andin-mold decorated article 10.

On the substrate sheet 51, an easily adherable layer may be formed sothat the decorating layer 50 firmly adheres thereto. Material of theeasily adherable layer may be given by polyester resin, acrylic resin,olefin resin, urethane resin or the like. The method for providing theeasily adherable layer may be a general printing process such as gravureprinting, screen printing or offset printing, or otherwise any ofvarious types of coating methods.

On the substrate sheet 51, a pattern layer 52 of characters, geometricpatterns, strips of contact print or the like is formed. As the materialof the pattern layer 52, usable are acrylic resin, soluble cotton resin,polyurethane resin, chlorinated rubber resin, vinyl chloride-vinylacetate copolymer resin, polyamide resin, polyester resin, epoxy resinand the like, but this is not limitative.

The pattern layer 52 may include a metal film layer of aluminum, chrome,copper, nickel, indium, tin, silicon oxide or the like by vacuumdeposition or plating or other process. In this case, the metal filmlayer may be either allover or patterned.

Film thickness of the pattern layer 52 is preferably 0.5 μm to 50 μm.Film thicknesses smaller than 0.5 μm would make it impossible to obtainenough design property, while film thicknesses larger than 50 μm wouldmake it difficult to dry the pattern layer after the printing. However,in the case of a metal film layer, the film thickness is preferably 50 Åto 1200 Å. Film thicknesses of the metal film layer smaller than 50 Åwould make it impossible to obtain enough metal lustrousness, while filmthicknesses larger than 1200 Å would cause cracks to occur more easily.

The method for providing the pattern layer 52 overall or in patterns maybe a general printing process such as gravure printing, screen printingor offset printing, or a metal film formation process such asTampo-printing, coating, various coating processes, evaporation, ionplating or sputtering.

The adhesion layer 53 has a function of bonding the decorating film 5and the molding resin 4 to each other. The material of the adhesionlayer 53 may be given desirably by using acrylic resin, soluble cottonresin, polyurethane resin, chlorinated rubber resin, vinylchloride-vinyl acetate copolymer resin, polyamide resin, polyesterresin, epoxy resin, polycarbonate resin, olefin resin, acrylonitrilebutadiene styrene resin, or the like.

The thickness of the adhesion layer 53 is preferably 0.5 to 50 μm. Filmthicknesses smaller than 0.5 μm would make it impossible to obtainenough adhesion property, while film thicknesses larger than 50 μm wouldmake it difficult to dry the adhesion layer after the printing. Themethod for forming the adhesion layer 53 may be a general printingprocess such as gravure printing, offset printing or screen printing, orany of coating, dipping, reverse coater or the like.

In addition, when only the decorating layer 50 in the decorating film 5is bonded to the molding resin 4, a peel-off layer 54 may be providedbetween the substrate sheet 51 and the pattern layer 52 as shown in FIG.17. Otherwise, the substrate sheet 51 may be provided with a moldrelease layer 55 so as to be a substrate sheet having moldreleasability.

The material of the peel-off layer 54 may be given by using acrylicresin, soluble cotton resin, polyurethane resin, chlorinated rubberresin, vinyl chloride-vinyl acetate copolymer resin, polyamide resin,polyester resin, epoxy resin, polycarbonate resin, olefin resin,acrylonitrile butadiene styrene resin, or the like.

The thickness of the peel-off layer 54 is preferably 0.5 to 50 μm. Filmthicknesses smaller than 0.5 μm would make it impossible to obtainenough adhesion property, while film thicknesses larger than 50 μm wouldmake it difficult to dry the peel-off layer after the printing,disadvantageously. The method for forming the mold release layer 55 maybe a general printing process such as gravure printing, offset printingor screen printing, or any of coating, dipping, reverse coater or thelike.

The material of the mold release layer 55 may be given desirably byusing acrylic resin, soluble cotton resin, polyurethane resin,chlorinated rubber resin, vinyl chloride-vinyl acetate copolymer resin,polyamide resin, polyester resin, epoxy resin, polycarbonate resin,olefin resin, acrylonitrile butadiene styrene resin, or the like.

The thickness of the mold release layer 55 is preferably 0.5 to 50 μm.Film thicknesses smaller than 0.5 μm would make it impossible to obtainenough adhesion property, while film thicknesses larger than 50 μm wouldmake it difficult to dry the mold release layer after the printing,disadvantageously. The method for forming the mold release layer 55 maybe a general printing process such as gravure printing, offset printingor screen printing, or any of coating, dipping, reverse coater or thelike.

In addition, in the decorating film 5 of such a structure as shown inFIG. 16, it is desirable that the substrate sheet 51 or the adhesionlayer 53 be transparent or semitransparent to form specified patterns bythe pattern layers 52. Also, in the decorating film 5 of such astructure as shown in FIG. 17, it is preferable that the peel-off layer54 or the adhesion layer 53 be transparent or semitransparent.

SECOND EMBODIMENT

It is noted here that the present invention is not limited to theforegoing embodiment but may be embodied in other various modes. Forexample, the manufacturing method for injection-molded and in-molddecorated articles according to a second embodiment of the invention canbe said to be generally similar in constitution to the method of thefirst embodiment in terms of using a first mold element and a secondmold element as well as a decorating film, but differs therefrom in thatthe first mold element and the second mold element are placed inopposition to each other with the decorating film interposedtherebetween, in which state, without performing the clamping and withthe molds opened, injection of the molding resin is performed. That is,this second embodiment adopts a so-called compression-method injectionmolding (injection compression molding) that in a state that the moldingspace formed between the first mold element and the decorating film isopen (i.e., in an open-space state), the injection of molding resin isperformed, and thereafter those molds are clamped, by which the moldingresin filled in the molding space is compressed by reducing the capacityof the molding space. In this point, the method of the second embodimentdiffers from that of the first embodiment that adopts an injectionmolding in which molding resin is injected into the closed molding spaceand thereafter injection molding is performed without being accompaniedby any reduction change of the capacity of the molding space.Hereinbelow, the description will be given mainly on this differencepoint, while the description of the first embodiment should be referredto for the same components as in the first embodiment. In addition, withregard to the structures of the molds and the decorating film in thesecond embodiment, structural components similar to those of the firstembodiment are designated by the same reference numerals as in the firstembodiment for an easier understanding of those structures.

First, as schematic explanatory views schematically showing amanufacturing method for injection-molded and in-mold decorated articlesaccording to this second embodiment, schematic sectional views of afirst mold element and a second mold element are shown in FIGS. 18, 19,20 and 21. Also, a schematic plan view of the first mold element isshown in FIG. 22.

The first mold element 71, as shown in FIG. 22, has a generallyquadrilateral, flat shape, as the first mold element 1 of the firstembodiment, and at its four peripheral end portions, a reference surface11 which makes direct contact with the second mold element 72. In aninner portion surrounded by the reference surface 11 are formed arecessed portion 12 having a configuration corresponding to the externalshape of the resin molded article, a mold touch sensor 77, and astretching recess 15. The mold touch sensor 77 is a sensor for, beforethe first mold element 71 and the second mold element 72 placed inopposition to each other are completely clamped, making contact with arecessed surface 21 of the second mold element 72 to provide amold-touch state, and injecting molding resin 4 while maintaining thegap distance between the first mold element 71 and the second moldelement 72 at a specified length. In addition, although the secondembodiment is described on a case where the mold touch sensor 77 isprovided on the first mold element 71, yet the mold touch sensor 77 mayalso be provided on the second mold element 72. Otherwise, the firstmold element 71 and the second mold element 72 are similar in structureto the first mold element 1 and the second mold element 2 of the firstembodiment.

As a result of the placement of the first mold element 71 and the secondmold element 72 having the structure shown above and placed inopposition to each other with the decorating film 5 interposedtherebetween, as shown in FIG. 19, a molding space 83 can be formed asin the first embodiment. This molding space 83, as in the firstembodiment, includes product molding spaces 91, a resin-injection-usemolding space 92 and a resin-discharging-use molding space 93, theplanar arrangement of these molding spaces being also similar to that ofthe first embodiment.

A method for manufacturing an injection-molded and in-mold decoratedarticle 80 by using the first mold element 71, the second mold element72 and the decorating film 5 of the structure shown above is describedin detail below.

First, as shown in FIG. 18, the first mold element 71 and the secondmold element 72 having structures shown above are placed in oppositionto each other so that their respective recessed portions 12, 22 confronteach other, and the decorating film 5 is placed between the first moldelement 71 and the second mold element 72 so that the surface on whichthe decorating layer 50 is provided is positioned on the first moldelement 71 side. In this process, positioning of the reference surfaces11, 21 as well as positioning of the decorating film 5 are fulfilledconcurrently.

After this positioning, as shown in FIG. 19, the first mold element 71and the second mold element 72 are made to approach each other, so thata fore end of the mold touch sensor 77 provided on the reference surface11 of the first mold element 71 is brought into contact with thereference surface 21 of the second mold element 72 directly or via thedecorating film 5. As this contact is detected by an unshown controlunit, the approach is stopped so that a specified distance is heldbetween the first mold element 71 and the second mold element 72.

In this holding state, as shown in FIG. 19, injection of molten moldingresin 4 into the molding space 83 that have been maintained open isstarted. The molding resin 4 injected through the gate portion 14 isinjected first into the resin-injection-use molding space 92, pressingthe decorating film 5 toward the second mold element 72 side, by whichthe pressed decorating film 5 is brought into contact with thepartitioning protrusions 23 and moreover fixed by the suction pins 25.Thereafter, through clamping, the molten molding resin 4 fills theresin-injection-use molding space 92 in vicinities of the gate portion14 and moreover enters the individual product molding spaces 91 beyondthe partitioning protrusions 23 on the vicinities side.

In this operation, the molten molding resin 4 increasingly fills themolding space 83 while pressing and gradually stretching the decoratingfilm 5 with the partitioning protrusions 23, thus making the decoratingfilm 5 less likely to loosen. Accordingly, small wrinkles less occur tothe decorating film 5 surrounded by the individual partitioningprotrusions 23.

Then, after the molten molding resin 4 has filled the product moldingspaces 81, or as this filling goes on, as shown in FIG. 20, part of themolding resin 4 filled into the product molding spaces 91 enters intothe resin-discharging-use molding space 93, so that the overall moldingspace 83 is filled with the molding resin 4. As this filling goes on,the first mold element 71 and the second mold element 72 with theirspecified distance maintained are made to further approach each other sothat the reference surface 11 of the first mold element 71 and thereference surface 21 of the second mold element 72 are brought intocontact with each other via the decorating film 5. As a result of this,the capacity of the molding space 83 with the molding resin 4 filledtherein is reduced and moreover the molding space 83 is changed fromopen to close state. Thus, the molding resin 4 filled in the moldingspace 83 is compressed so as to be filled allover to every corner of themolding space 83, and moreover the molding resin 4 is compacted tohigher density. Also, in the process of such filling, most of the gasesgenerated from the molding resin 4 are converged to theresin-discharging-use molding space 93. Also, in cases where occurrenceof welds is involved, sites of occurrence of welds are shifted into theresin-discharging-use molding space 93. In addition, flow directions ofthe molding resin 4 filled into the molding space 83 in the process offilling of the molding resin 4 are similar to the flow directions F1described in the first embodiment (see FIG. 12).

After the molding resin has been filled into the molding space 83 inthis way, the molding resin 4 that has been in the molten state iscooled and solidified. Thereafter, as shown in FIG. 21, as the clampingof the first mold element 71 and the second mold element 72 is released,the ejector pins 24 are projected, causing the injection-molded andin-mold decorated article 80 to be released from the mold. Thedecorating layers 50 of the decorating film 5 are peeled off from thesubstrate sheet 51 and resultantly fixed to the surface of theinjection-molded and in-mold decorated article 80 that has been incontact with the decorating film 5. Thus, the decoration on theinjection-molded and in-mold decorated article 80 has been achieved.

Thereafter, the injection-molded and in-mold decorated article 80 is cutinto the product molded article portions and the outer-frame moldedarticle potions, by which the product molded article portions areobtained, respectively, as in the first embodiment.

According to the second embodiment, in the process of injection of themolding resin 4 into the molding space 83, the molding space 83 is setto an open state, and after the filling of the molding resin 4, thefirst mold element 71 and the second mold element 72 that have been inthe open state are clamped, by which the molding space 83 is put into ahermetically closed state and moreover the capacity of the molding space83 is reduced. As a result of this, the filled molding resin 4 can becompressed so as to extend allover to every corner of the molding space83. Such an effect becomes greater particularly in cases where themolding space 83 is a thin-type space so that an even-state injection ofthe molding resin 4 is difficult to achieve. Also, since the moldingresin 4 can be compressed, it becomes practicable to form high-densitymolded articles, so that this method is suitable as a manufacturingmethod in cases where the injection-molded and in-mold decorated article80 is an optical lens or other optical system component or the like.

Besides, although this second embodiment has been described on a case ofan injection compression molding in which with the first mold element 71and the second mold element 72 maintained at specified distancetherebetween and with the molding space 83 in an open state, theinjection of the molding resin 4 is performed and thereafter the firstmold element 71 and the second mold element 72 are clamped so that thecapacity of the molding space 83 is reduced and moreover hermeticallyclosed, yet the injection compression molding is not limited to such acase only. Instead of such a case, it is also possible that, forexample, with the first mold element provided so as to be partlymovable, the first mold element and the second mold element are clampedto form a hermetically closed molding space, thereafter the injection ofmolding resin is performed, and then the part of the first mold elementis moved, by which the capacity of the molding space is reduced tocompress the filled molding resin.

WORKING EXAMPLES OF MOLDING SPACE

Next, various working examples of the arrangement of the molding spacedefined by the first mold element and the decorating film, which hasbeen described in the individual embodiments of the present invention,are described with reference to spatial arrangement views.

Working Example 1

The foregoing embodiments have been described on a case where themolding space 3 has the four product molding spaces 31, theresin-injection-use molding space 32 and the resin-discharging-usemolding space 33. However, the invention is not limited to such caseswhere a plurality of product molding spaces are included and moreoverthe resin-injection-use molding space is further included, but variousaspects are conceivable.

Now a spatial arrangement view (schematic plan view) of a molding space110 according to Working Example 1 is shown in FIG. 23. As shown in FIG.23, the molding space 110 has one product molding space 111 and aresin-discharging-use molding space 113. More specifically, the productmolding space 111 is a space having a generally square shape, as viewedin a plan view, and the resin-discharging-use molding space 113 isplaced so as to surround the entire outer periphery of the productmolding space 111. Further, a gate portion 114 is placed at a place neara lower center of the product molding space 111 as viewed in the figure.

By such makeup of the molding space 110, molding resin injected into theproduct molding space 111 through the gate portion 14 is filled into theproduct molding space 111 while spreading generally radially from thegate portion 14. It is noted that flow directions F2 of the moldingresin are shown by arrows in FIG. 23. Along with this filling, part ofthe molding resin filled into the product molding space 111 flows intothe adjacently placed resin-discharging-use molding space 113, so thatthe molding resin is filled into the overall molding space 110.

In the molding space 110 of such a constitution, generated gases can beconcentrated to the resin-discharging-use molding space 113 while themolding resin is being spread radially, and besides there never occursany weld within the product molding space 111. However, since the gateportion 114 is placed in the product molding space 111, there remains amark of the gate portion 114 in the surface of the formed moldedarticle. For this reason, the placement of the gate portion 114 withinthe product molding space 111 needs to be determined in consideration ofthe presence of such a mark. For instance, as shown in FIG. 23, in acase where a portion where the mark should not be formed in the moldedarticle, e.g., a transparent window portion 111 a for visual recognitionis formed at an upper place in the figure within the product moldingspace 111, the gate portion 114 may well be placed at a lower place inthe figure so as to avoid the transparent window portion 111 a.

According to this Working Example 1, the molding space 110 can beeffectively utilized to the extent that the resin-injection-use moldingspace is not provided, allowing the metal mold for injection-moldingwith in-mold decoration to be reduced in size.

Working Example 2

Next, a spatial arrangement view (schematic plan view) of a moldingspace 120 according to Working Example 2 is shown in FIG. 24. As shownin FIG. 24, the molding space 120 has one product molding space 121, aresin-injection-use molding space 122, and a resin-discharging-usemolding space 123. More specifically, the resin-injection-use moldingspace 122 having a generally triangular spatial shape, as viewed in aplan view, is placed so as to be adjacent to and communicative with alower-in-the-figure end portion of the product molding space 121, whichis a space generally square shaped, as viewed in a plan view. Also, theresin-discharging-use molding space 123 is placed so as to be adjacentto and communicative with the remaining three-side end portions of theproduct molding space 121. Moreover, the gate portion 124 is placed neara lower place of the resin-injection-use molding space 122 as viewed inthe figure.

By such makeup of the molding space 120, molding resin injected into theresin-injection-use molding space 122 through the gate portion 124 isfilled into the resin-injection-use molding space 122 while spreadinggenerally radially from the gate portion 124 toward the product moldingspace 121, as shown by flow directions F3 of the molding resin in FIG.24. Further, the molding resin filled into the resin-injection-usemolding space 122 flows into the product molding space 121, being filledinto the product molding space 121. Thereafter, part of the filledmolding resin flows from the product molding space 121 into theresin-discharging-use molding space 123, by which the molding resin isfilled in the overall molding space 120.

According to this Working Example 2, in the molding space 120, generatedgases can be concentrated to the resin-discharging-use molding space 123while the molding resin is being spread radially, and besides therenever occurs any weld within the product molding space 121. Further,since the gate portion 124 is placed in the resin-injection-use moldingspace 122, the product molding space 121, on which the decoration is tobe applied, can be placed apart from the product molding space 121, thussuppressing breakage (e.g., ink flow) of the decorating layer due to theinjection of high-pressure molding resin performed through the gateportion 124, so that reliable decoration can be fulfilled. Furthermore,since there never occurs any mark of the gate portion 124 on the surfaceof the molded article formed within the product molding space 121, forexample, a transparent window portion 121 a for visual recognition canbe formed so as to occupy a generally entirety of the molded articleformed by the product molding space 121.

Working Example 3

Next, a spatial arrangement view of a molding space 130 according toWorking Example 3 is shown in FIG. 25. As shown in FIG. 25, the moldingspace 130 of this Working Example 3, which has such an arrangement asjuxtaposition of two molding spaces 110 of Working Example 1, includestwo product molding spaces 131 and resin-discharging-use molding spaces133 which are so placed as to surround the product molding spaces 131,respectively, integrally in communication therewith. Further, a gateportion 134 is placed at a place near a lower center of each productmolding space 131 as viewed in the figure.

By such makeup of the molding space 130, molding resin injected into theproduct molding spaces 131 through the gate portions 134, respectively,is filled into the individual product molding spaces 131 while spreadinggenerally radially from the gate portions 134 (see flow directions F4 ofthe molding resin shown in FIG. 25). Along with this filling, part ofthe molding resin filled into the individual product molding spaces 131flows into the resin-discharging-use molding spaces 133 that isadjacently placed so as to surround those resin-discharging-use moldingspaces, being filled into the overall molding space 130.

According to this Working Example 3, effects similar to those of WorkingExample 1 can be obtained, and the molding space 130 can be effectivelyutilized to the extent that the resin-injection-use molding space is notprovided, allowing the metal mold to be reduced in size. Preferably, theplacement of the gate portions 134 in the product molding spaces 131,respectively, is determined in consideration of the placement ofrespective transparent window portions 131 a for visual recognition, andmoreover with the placement of the gate portions 134 left-rightsymmetrical, fore end portions of the molding resin injected throughthose gate portions 134 are positioned at the resin-discharging-usemolding spaces 133 placed between the product molding spaces 131.

Working Example 4

Next, a spatial arrangement view of a molding space 140 according toWorking Example 4 is shown in FIG. 26. As shown in FIG. 26, the moldingspace 140 has juxtaposed two product molding spaces 141, aresin-injection-use molding space 142 which is placed between theproduct molding spaces 141 and which is adjacent to and communicativewith the individual product molding spaces 141, and tworesin-discharging-use molding spaces 143 which are placed adjacent toand communicative with the individual product molding spaces 141 so asto surround peripheries of the product molding spaces 141, exceptportions where the resin-injection-use molding space 142 is provided.Further, a gate portion 144 is placed at a place near a generally centerof the resin-injection-use molding space 142.

By such makeup of the molding space 140, molding resin injected into theresin-injection-use molding space 142 through the gate portion 144, isfilled into the resin-injection-use molding space 142 while spreadinggenerally radially from the gate portion 144. Further, the molding resinfilled in the resin-injection-use molding space 142 flows into theindividual product molding spaces 141, being filled into the individualproduct molding spaces 141. Thereafter, part of the filled molding resinflows from the product molding spaces 141 into the resin-discharging-usemolding spaces 143, respectively, by which the molding resin is filledin the overall molding space 140 (see flow directions F5 of the moldingresin shown in FIG. 26).

According to this Working Example 4, effects similar to those of WorkingExample 2 can be obtained, and it is also made possible that while theproduct molding spaces 141 are provided two in number, only one gateportion 144 is provided only one, thus making possible to simplify thesprue runner, which is the injection path for the molding resin to thegate portion 144. As a result of this, the amount of the molding resinthat remains in the sprue runner can be reduced. Also, since there neverremains any mark of the gate portion 144 in the surfaces of the moldedarticles formed in the individual product molding spaces 141, forexample, transparent window portions 141 a for visual recognition can beformed so as to occupy generally entireties of the molded articlesformed by the product molding spaces 141, respectively.

Working Example 5

Next, a spatial arrangement view of a molding space 150 according toWorking Example 5 is shown in FIG. 27. As shown in FIG. 27, the moldingspace 150 of this Working Example 5 includes juxtaposed two productmolding spaces 151, and a resin-discharging-use molding space 153 whichis so placed as to partly surround outer peripheries of the individualproduct molding spaces 151 and to be adjacent to and communicativetherewith in a range between the individual product molding spaces 151and in their vicinities. Further, a gate portion 154 is placed near aleftward center of the left-hand product molding space 151, and a gateportion 154 is placed near a rightward center of the right-hand productmolding space 151, as viewed in the figure.

By such makeup of the molding space 150, molding resin injected into theproduct molding spaces 151 through the gate portions 154, respectively,is filled into the individual product molding spaces 131 while spreadinggenerally radially from the individual gate portions 154 toward thecenter of the molding space 150, being filled into the individualproduct molding spaces 151. Along with this filling, part of the moldingresin filled into the individual product molding spaces 151 flows intothe adjacently placed resin-discharging-use molding space 153, by whichthe molding resin is filled into the overall molding space 150 (see flowdirections F6 of the molding resin shown in FIG. 27).

According to this Working Example 5, effects similar to those of WorkingExamples 1 and 3 can be obtained, and the molding space 150 can beeffectively utilized to the extent that the resin-injection-use moldingspace is not provided, allowing the metal mold to be reduced in size.Preferably, the placement of the gate portions 154 in the productmolding spaces 151, respectively, is determined in consideration of theplacement of respective transparent window portions 151 a for visualrecognition.

Working Example 6

Next, a spatial arrangement view of a molding space 160 according toWorking Example 6 is shown in FIG. 28. As shown in FIG. 28, the moldingspace 160, which has an arrangement that two molding spaces 120 ofWorking Example 2 are juxtaposed and opposed to each other, includes twoproduct molding spaces 161, two resin-injection-use molding spaces 162adjacent to and communicative with the product molding spaces 161,respectively, and a resin-discharging-use molding space 163 which isplaced between the individual product molding spaces 161 so as to partlysurrounds the individual product molding spaces 161 and which isintegrally formed adjacent to and communicative with the product moldingspaces 161. Further, gate portions 164 are provided in theresin-injection-use molding spaces 162, respectively.

By such makeup of the molding space 160, molding resin injected into theindividual resin-injection-use molding spaces 162 through the gateportions 164, respectively, is filled into the individualresin-injection-use molding spaces 162 while spreading generallyradially from the individual gate portions 164 toward then adjacentproduct molding spaces 161, being filled into the individualresin-injection-use molding spaces 162. Further, the molding resinfilled into the individual resin-injection-use molding spaces 162 flowsinto their adjacent product molding spaces 161, respectively, beingfilled into the individual product molding spaces 161. Thereafter, partof the filled molding resin flows from the individual product moldingspaces 161 into the resin-discharging-use molding space 163, by whichthe molding resin is filled into the overall molding space 160 (see flowdirections F7 of the molding resin shown in FIG. 28).

According to this Working Example 6, even if two product molding spacesare provided, effects similar to those of Working Example 2 can beobtained. Also, since there never occurs any mark of the gate portions164 on the surface of the molded article formed within the productmolding space 161, for example, a transparent window portion 161 a forvisual recognition can be formed so as to occupy a generally entirety ofthe molded article formed by the product molding space 161.

Working Example 7

Next, a spatial arrangement view of a molding space 170 according toWorking Example 7 is shown in FIG. 29. As shown in FIG. 29, the moldingspace 170 of this Working Example 7, which has an arrangement that themolding space 110 of Working Example 1 is arrayed and placed four innumber around the center of the molding space 170, includes four productmolding spaces 171, and a resin-discharging-use molding space 173 whichis placed integrally communicatively so as to surround entireperipheries of the individual product molding spaces 171. Further, gateportions 174 are provided at places in the individual product moldingspaces 171 near the center of the molding space 170, respectively.

By such makeup of the molding space 170, molding resin injected into theindividual product molding spaces 171 through the gate portions 174,respectively, is filled into the individual product molding spaces 171while spreading generally radially from the individual gate portions174. Along with this filling, part of the molding resin filled into theindividual product molding spaces 171 flows into theresin-discharging-use molding space 173 that is adjacently plated so asto surround the product molding spaces 171, by which the molding resinis filled into the overall molding space 170 (see flow directions F8 ofthe molding resin shown in FIG. 29).

According to this Working Example 7, even if a plurality of productmolding spaces 171 are included provided, effects similar to those ofWorking Example 1 can be obtained, and moreover the molding space 170can be effectively utilized to the extent that the resin-injection-usemolding space is not provided, allowing the metal mold to be reduced insize. Preferably, the placement of the gate portions 174 in theindividual product molding spaces 171, respectively, is determined so asto be centrosymmetrical with a reference position given by the center ofthe molding space 170, in consideration of the placement of respectivetransparent window portions 171 a for visual recognition.

Working Example 8

Next, a spatial arrangement view of a molding space 180 according toWorking Example 8 is shown in FIG. 30. As shown in FIG. 30, the moldingspace 180 is obtained by applying the arrangement of the molding space140 of Working Example 4 to a case where four product molding spaces 181are provided. That is, the molding space 180 includes four productmolding spaces 181 which are arrayed and placed around the center of themolding space 180, a resin-injection-use molding space 182 having aspace which is formed between two product molding spaces 181 placed inthe right hand in the figure and which is adjacent to and communicativewith the right side thereof and a space which is placed symmetrical withthe two product molding spaces 181 placed on the left side in thefigure, and a resin-discharging-use molding space 183 which isintegrally placed between and above and below right and left arrays ofthe product molding spaces 181 so as to be adjacent to and communicativetherewith. Further, gate portions 184 are provided at a place near aright-side generally center of the right-hand placed resin-injection-usemolding space 182, and a place near a left-side generally center of theleft-hand placed resin-injection-use molding space 182, respectively, asviewed in the figure.

By such makeup of the molding space 180, molding resin injected into theindividual resin-injection-use molding spaces 182 through the gateportions 184, respectively, is filled into the individualresin-injection-use molding spaces 182 while spreading generallyradially from the gate portions 184. Further, the molding resin filledinto the individual resin-injection-use molding spaces 182 flows intothe individual product molding spaces 181, respectively, being filledinto the individual product molding spaces 181. Thereafter, part of thefilled molding resin flows from the individual product molding spaces181 into the resin-discharging-use molding space 183, by which themolding resin is filled into the overall molding space 180 (see flowdirections F9 of the molding resin shown in FIG. 30).

According to this Working Example 8, effects similar to those of WorkingExample 4 can be obtained. Also, since there never occurs any mark ofthe gate portions 184 on the surfaces of the molded articles formedwithin the individual product molding spaces 181, for example,transparent window portions 181 a for visual recognition can be formedso as to occupy generally entireties of the molded articles formed bythe individual product molding spaces 181, respectively.

Working Example 9

Next, a spatial arrangement view of a molding space 190 according toWorking Example 9 is shown in FIG. 31. As shown in FIG. 31, the moldingspace 190 is a modification of the arrangement of the molding space 180of Working Example 8. More specifically, resin-injection-use moldingspaces 192 are provided in correspondence to the four product moldingspaces 191, respectively. Also, a resin-discharging-use molding space193 is formed as a generally cross shaped so as to be placed between theindividual product molding spaces 191. Further, gate portions 194 areplaced in the individual resin-injection-use molding spaces 192,respectively, so as to be positioned near four corner portions of themolding space 190.

Also with the molding space 190 having such an arrangement as shownabove, flows of the molding resin as shown by flow directions F10 ofFIG. 31 can be fulfilled, so that effects similar to those of WorkingExamples 8 can be obtained. Also, since there never occurs any mark ofthe gate portions 194 on the surfaces of the molded articles formedwithin the individual product molding spaces 191, for example,transparent window portions 191 a for visual recognition can be formedso as to occupy generally entireties of the molded articles formed bythe individual product molding spaces 191.

Working Examples 10, 11

Furthermore, the arrangement construction of the molding space accordingto the individual embodiments described above are not limited to thenumbers of product molding spaces, and may be applied to cases whereeven larger numbers of product molding spaces are provided. For example,a spatial arrangement view of a molding space 200 according to WorkingExample 10 is shown in FIG. 32, and a spatial arrangement view of amolding space 210 according to Working Example 11 is shown in FIG. 33.

As shown in FIGS. 32 and 33, even in the cases where six product moldingspaces 201, 211 are provided, there can be formed molding spaces havingthe effects of the foregoing working examples.

Working Example 12, 13

Furthermore, with such a molded article as shown above, it is alsopossible that its central portion is cut and removed to form the moldedarticle. As such a case, a spatial arrangement view of a molding space220 according to Working Example 12 is shown in FIG. 34. As shown inFIG. 34, the molding space 220 is formed of a product molding space 221,which is a generally square-shaped space, and a resin-injection-usemolding space 223 which is placed adjacent to and communicative with themolding space 220 so as to surround its entire periphery. Further, fourgate portions 224 are provided in the resin-injection-use molding space223 so as to be placed at its corner portions.

In the molding space 220 of such an arrangement, molding resin injectedthrough the four gate portions 224 is filled into theresin-injection-use molding space 223, and moreover the molding resinflows into the product molding space 221 in flow directions F13 from theresin-injection-use molding space 223 toward the center of the moldingspace 220, by which the molding resin is filled in the overall moldingspace 220.

With such flow directions F13 of the molding resin, collisions of themolding resin itself occur at places near the center of the productmolding space 221, causing welds to occur. However, since a boredportion 221 a is placed near the center of the molded article formed bythe product molding space 221, welds, even if it has occurred, isremoved, causing no problems.

Also, it is also possible that as shown in a spatial arrangement view ofa molding space 230 according to Working Example 13 of FIG. 35, a boredportion 231 a is placed near a generally center of the molded articleformed by a product molding spaces 231, and moreover a gate portion 234is placed so as to correspond to the bored portion 231 a. In such acase, any mark of the gate portion 234 can be removed by removal of thebored portion 231 a while generally radial flow directions F14 from thegate portion 234 are fulfilled, advantageously.

(Form of Molded Article)

Next, various examples of the form of the injection-molded and in-molddecorated article formed by the manufacturing method of the individualembodiments described above or others are described with reference toschematic views of injection-molded and in-mold decorated articles shownin FIGS. 36A, 36B, 36C and 36D. In the drawings of FIGS. 36A to 36D,portions of the injection-molded and in-mold decorated article otherthan transparent window portions are hatched with a view to visuallyclearly distinguishing the transparent window portions and the otherportions from each other.

First, an injection-molded and in-mold decorated article 301 shown inFIG. 36A is a molded article having no transparent window portions. Thismolded article is exemplified by molded articles for which marks ofwelds, resin burns or the like should not be left on their surfaces,such as automobile parts, household electrical appliances, constructionmaterials and livingwares, as well as general molded articles.

Next, an injection-molded and in-mold decorated article 302 shown inFIG. 36B is a molded article in which a transparent window portion 302 ais formed generally all over the molded article. Such a transparentportion 302 a is characterized by being a portion which is used commonlyfor visual recognition and in which marks of welds or resin burns or thelike should not be left on its surface and in its interior and moreoverwhich is formed into a thin portion. This injection-molded and in-molddecorated article 302 is exemplified by information display windowportions of personal digital assistants such as portable telephones, anddisplay portions of personal computers, small-size televisions.

Next, an injection-molded and in-mold decorated article 303 shown inFIG. 36C is a molded article in which a transparent window portion 303 ais formed as a little portion of the molded article. Such a transparentportion 303 a is characterized by being a portion which is used commonlyfor visual recognition and in which marks of welds or resin burns or thelike should not be left on its surface and in its interior and moreoverwhich is formed into a thin portion. This injection-molded and in-molddecorated article 303 is exemplified by input panels of electricalappliances (e.g., rice cookers, washing machines).

Next, an injection-molded and in-mold decorated article 304 shown inFIG. 36D is a molded article which is formed entirely as a transparentwindow portion. Such an injection-molded and in-mold decorated article304 is exemplified by optical products such as lenses.

(Form of Partitioning Protrusions)

Next, various examples of the form of the partitioning protrusions 23formed in the second mold element 2, 72 used in the foregoing individualembodiments are described. In the drawings used in the followingdescription, the partitioning protrusions 23 are hatched with a view tovisually clarifying the partitioning protrusions 23.

The second mold element 2 of the first embodiment shown in FIG. 7 hasbeen described on a case where the partitioning protrusions 23 areplaced so as to surround the entire peripheries of the product moldingspaces 31, respectively. However, the placement of the partitioningprotrusions 23 is not limited to such a case, but other variousplacements may be adopted.

For example, as shown in FIG. 37, the case may be that partitioningprotrusions 351 are placed so as to surround peripheries of theindividual product molding spaces 31 but not placed only at cornerportions of the product molding spaces 31.

Also, as shown in FIG. 38, the case may be that partitioning protrusions352 are placed so as to generally surround peripheries of the individualproduct molding spaces 31 but formed in a combination of protrudedportions of continuous formation and bump portions of discontinuousformation.

Also, shown in FIG. 39, the case may be that partitioning protrusions353 are so formed that generally circular-shaped discontinuous bumpportions surround peripheries of the individual product molding spaces31.

Also, as shown in FIG. 40, the case may be that partitioning protrusions354 are so formed that individual product molding spaces 31 aresurrounded double and that individual bump portions of the doublesurrounding differ in arrangement pattern thereamong.

Also, as shown in FIG. 41, the case may be that partitioning protrusions355 are formed so that their bump portions differ in width thereamongdepending on site.

In particular, as the likelihood of loosenesses of the decorating film 5may differ depending on the shape or site of molded articles, occurrenceof loosenesses of the decorating film 5 can be prevented by changing theform of the partitioning protrusions according to the shape of themolded articles or the like. Further, with a high likelihood thatwrinkles or loosenesses may occur, the likelihood can be suppressed bylaying out the partitioning protrusions continuously in two arrays andmoreover increasing the width of their bump portions. With anunlikelihood of occurrence of such wrinkles or loosenesses, it isallowable that the partitioning protrusions are formed in one array ornot provided.

(Arrangement Form of Suction Pins)

Next, variations of the arrangement form of the suction pins formed inthe second mold element 2, 72 in the foregoing individual embodimentsare described. In the drawings described later, the partitioningprotrusions 23 and the suction pins 25 are hatched with a view tovisually clarifying the partitioning protrusions 23 and the suction pins25.

For example, as shown in FIG. 42, suction pins 25 may be placed at thefour corners and near the centers of the side edges inside thepartitioning protrusion 23.

Also, as shown in FIG. 43, a large number of suction pins 25 may beplaced so as to be generally uniformly laid out in a region defined bythe product molding space 31 inside the partitioning protrusion 23.

Also, as shown in FIG. 44, in a case where the partitioning protrusions23 are not present, individual suction pins 25 may be laid out uniformlyin the vicinity of the outer periphery of the product molding space 31.

Also, as shown in FIG. 45, in a case where there is a large regionbetween the inner periphery of the partitioning protrusion 23 and theouter periphery of the product molding space 31, suction pins 25 may belaid out in vicinities of the partitioning protrusion 23 and vicinitiesof the product molding space 31 so that a reliable holding of thedecorating film 5 can be fulfilled.

Also, in such a case, as shown in FIG. 46, suction pins 25 may beprovided on inner and outer sides of the four corner portions of thepartitioning protrusion 23.

In particular, there are some cases where the subordination of thedecorating film 5 to the second mold element 2 differs among sites, inwhich case there is a need for preventing occurrence of wrinkles orloosenesses in the product molding spaces 31. Since the subordination ofthe decorating film 5 to the metal mold becomes poor in vicinities ofthe partitioning protrusions 23 and increasingly with increasingcloseness to corner portions, the suction pins 25 are desirably providedat such portions. Further, the suction pins 25 are preferably set invicinities of the product molding spaces 31, which are objectiveportions where occurrence of wrinkles or the like should be prevented.

(Placement Mode of Stretching Recess)

Next, various placement modes of the stretching recess 15 formed on theperipheries of the molds 1, 2, 71, 72 in the foregoing embodiments aredescribed. In the drawings used in the following description, thestretching recess 15 is hatched with a view to visually clarifying thestretching recess 15.

For example, instead of the case where the stretching recess 15 isformed on the entire periphery of the mold, the case may be that, asshown in FIG. 47, stretching recesses 15 placed along the up-downdirection in the figure, which is the direction of feed of thedecorating film 5, are formed continuously while stretching recesses 15placed along the widthwise direction of the decorating film 5, which isthe direction perpendicular to the feed direction, are formeddiscontinuously.

Also, as shown in FIG. 48, the stretching recesses 15 may be changed inwidth between feed direction and widthwise direction of the decoratingfilm 5. For example, it is possible that the stretching recess 15 placedalong the feed direction is formed with a width larger than the widthfor the stretching recess 15 placed along the widthwise direction whilethe stretching recess 15 formed close to the molding space 3 and placedalong the widthwise direction is formed rather away from the moldingspace 3. Also, as shown in FIG. 49, the four corner portions of thestretching recess 15 shown in FIG. 48 may be deformed into a circularshape.

Loosening of the decorating film 5 differs between the feed direction,in which tensile force is applied to the decorating film 5, and thewidthwise direction, and moreover depending on the configuration of themolded article and the thickness and configuration of the stretchingrecess 15 as well as its distance to the molding space 3. Therefore, bythe adoption of such a placement mode of the stretching recess 15, itbecomes possible to prevent occurrence of looseness as much as possibleby selection of an optimum mode of the stretching recess 15 depending onvarious conditions of looseness. Furthermore, the placement mode of thestretching recess 15 is not limited to such cases as shown above, butthe case may be that the stretching recess 15 is provided in two arraysonly, or is not formed.

It is to be noted that, by properly combining the arbitrary embodimentsof the aforementioned various embodiments, the effects possessed by themcan be produced.

Although the present invention has been fully described in connectionwith the preferred embodiments thereof with reference to theaccompanying drawings, it is to be noted that various changes andmodifications are apparent to those skilled in the art. Such changes andmodifications are to be understood as included within the scope of thepresent invention as defined by the appended claims unless they departtherefrom.

1-15. (canceled)
 16. A manufacturing method for an injection-molded andin-mold decorated article, comprising: setting a decorating film betweena first mold element and a second mold element placed in opposition toeach other so that a molding space is defined by the decorating film andthe first mold element, the molding space including a product moldingspace and a resin-discharging-use molding space which is formed so as tobe adjacent to and communicative with at least part of a periphery ofthe product molding space and into which molten molding resin is let toflow for discharge of the molding resin from the product molding space;injecting the molten molding resin into the product molding space;discharging part of the injected molding resin from the product moldingspace into the resin-discharging-use molding space; completing fillingof the molding resin into the product molding space and theresin-discharging-use molding space; and solidifying the molding resinfilled in the molding space while decorating a surface of the moldingresin with the decorating film, so that the injection-molded and in-molddecorated article is manufactured.
 17. The manufacturing method for theinjection-molded and in-mold decorated article as defined in claim 16,wherein the molding space further includes a resin-injection-use moldingspace which is formed so as to be adjacent to and communicative with atleast part of a periphery of the product molding space and into whichthe molding resin is injected from outside of the molding space, themethod further comprising: after setting the decorating film so that themolding space including the product molding space, theresin-discharging-use molding space, and the resin-injection-use moldingspace, injecting the molding resin from outside of the molding spaceinto the resin-injection-use molding space; and making the injectedmolding resin flow from the resin-injection-use molding space into theproduct molding space, by which the injection of the molding resin intothe product molding space is fulfilled.
 18. The manufacturing method forthe injection-molded and in-mold decorated article as defined in claim17, wherein the molding space includes a first product molding space anda second product molding space as said product molding spaces, which arecommunicative with each other, and a common resin-injection-use moldingspace as said resin-injection-use molding space, the molding resin isinjected from outside of the molding space into the commonresin-injection-use molding space; the injected molding resin is let toflow from the common resin-injection-use molding space into the firstproduct molding space and the second product molding space, by whichfilling of the molding resin is fulfilled.
 19. The manufacturing methodfor the injection-molded and in-mold decorated article as defined inclaim 16, wherein the molding space includes a first product moldingspace and a second product molding space, which are communicative witheach other, and a common resin-discharging-use molding space as saidresin-discharging-use molding space, which is placed between the firstproduct molding space and the second product molding space and which iscommunicative with the first product molding space and the secondproduct molding space, the molding resin is injected into the firstproduct molding space and the second product molding space, part of themolding resin injected into the first product molding space and part ofthe molding resin injected into the second product molding space aredischarged into the common resin-discharging-use molding space, and thenfilling of the molding resin into the first product molding space, thesecond product molding space and the common resin-discharging-usemolding space is completed.
 20. The manufacturing method for theinjection-molded and in-mold decorated article as defined in claim 16,wherein the injection of the molding resin is performed in a state that,with the decorating film placed between the first mold element and thesecond mold element, the first mold element and the second mold elementare clamped to make the molding space hermetically closed.
 21. Themanufacturing method for the injection-molded and in-mold decoratedarticle as defined in claim 20, wherein, after the filling of themolding resin into the molding space, a capacity of the molding space isreduced while compressing the filled molding resin.
 22. Themanufacturing method for the injection-molded and in-mold decoratedarticle as defined in claim 16, wherein, with the decorating film isplaced between the first mold element and the second mold element andmaking the first mold element and the second mold element approached byeach other so as to be in a condition the molding space is opened, theinjection of the molding resin is performed, and thereafter the firstmold element and the second mold element is clamped so that a capacityof the molding space is reduced while compressing the filled moldingresin.
 23. A mold for injection-molding with in-mold decoration formanufacturing an injection-molded and in-mold decorated article,comprising: a first mold element; and a second mold element which isplaced in opposition to the first mold element with setting a decoratingfilm between the both mold elements, the first mold element comprising:a product molded article forming portion which is a recessed portionformed on a surface of the first mold element, for defining a productmolding space between the product molded article forming portion and thedecorating film with setting between the elements, the product moldingspace is part of a molding space and into which molten molding resin isinjected; and a discharge-space molded article forming portion which isa recessed portion formed on the surface of the first mold element, fordefining a resin-discharging-use molding space between thedischarge-space molded article forming portion and the decorating filmwith setting between the elements, the resin-discharging-use moldingspace is part of the molding space and is formed so as to be adjacent toand communicative with at least part of a periphery of the productmolding space and into which part of the molding resin injected into theproduct molding space is let to flow and discharged from the productmolding space, wherein with defining the product molding space and theresin-discharging-use molding space by setting the decorating filmbetween the both mold elements, part of the molding resin injected intothe product molding space is discharged from the product molding spaceinto the resin-discharging-use molding space, and then the molding resinfilled in the product molding space and the resin-discharging-usemolding space is solidified while decorating a surface of the moldingresin with the decorating film, so that the injection-molded and in-molddecorated article is manufactured.
 24. The mold for injection-moldingwith in-mold decoration as defined in claim 23, wherein the first moldelement further comprising an injection-space molded article formingportion which is a recessed portion formed on the surface of the firstmold element, for defining a resin-injection-use molding space betweenthe injection-space molded article forming portion and the decoratingfilm with setting between the elements, the resin-injection-use moldingspace is part of the molding space and is formed so as to becommunicative with at least part of the product molding space and intowhich the molding resin is injected from outside of the molding space,and moreover which lets the injected molding resin flow into the productmolding space so that injection of the molding resin into the productmolding space is fulfilled.
 25. The mold for injection-molding within-mold decoration as defined in claim 24, wherein the first moldelement comprising: a first said product molded article forming portionfor defining a first said product molding space; a second said productmolded article forming portion for defining a second said productmolding space which is communicative with the first product moldingspace; and a common said injection-space molded article forming portionfor defining a common said resin-injection-use molding space into whichthe molding resin is injected from outside of the molding space andwhich lets the injected molding resin injected into the first productmolding space and the second product molding space so that filling ofthe molding resin is fulfilled.
 26. The mold for injection-molding within-mold decoration as defined in claim 23, further comprising a filmholding portion which is formed as generally protruded portion on asurface of the second mold element, with which the decorating film inthe resin-discharging-use molding space is to be brought into contact bythe injection of the molding resin into the resin-discharging-usemolding space, and which serves to hold placement of the decorating filmwhile removing looseness of the decorating film by putting thedecorating film into close contact with a surface of the protrudedportion.
 27. The mold for injection-molding with in-mold decoration asdefined in claim 26, further comprising a plurality of suction portionswhich are set at the film holding portion or its vicinities in thesurface of the second mold element and which serve for sucking andholding the decorating film in contact therewith.
 28. The mold forinjection-molding with in-mold decoration as defined in claim 23,wherein either one of the first mold element or the second mold elementfurther comprising: a recess portion formed along an entirety or part ofan outer periphery of the molding space thereon; and a protrudedengagement portion which is formed on the other of the first moldelement or the second mold element so as to correspond to the placementof the recessed portion and engage with the recess portion in theclamping state of the first mold element and the second mold element,wherein in the clamping state of the first mold element and the secondmold element with the decorating film interposed therebetween, tensionis imparted to the decorating film by making the recessed portion andthe engagement portion engaged with each other via the decorating film.29. The mold for injection-molding with in-mold decoration as defined inclaim 23, further comprising an air vent portion for discharging gaspresent in the resin-discharging-use molding space to outside of themolding space in a vicinity of a boundary with the product molding spacein the resin-discharging-use molding space.
 30. The mold forinjection-molding with in-mold decoration as defined in claim 23,wherein the first mold element comprising: a first said product moldedarticle forming portion for defining a first said product molding space;a second said product molded article forming portion for defining asecond said product molding space which is communicative with the firstproduct molding space; and a common said discharge-space molded articleforming portion for defining a common said resin-discharging-use moldingspace into which part of the molding resin injected into the firstproduct molding space and part of the molding resin injected into thesecond product molding space are discharged and let to flow.